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BAE Systems PPAP Guide Doc #: B45157

May 24, 2018 of 28

Author: Pete Trainor

SUMMARY

The purpose of the PPAP Submission Guide is to assist the supplier to complete the various aspects of the Enhanced First Article (PPAP).

SUPPLIER

http://onespace.baesystems.com/ES/locations/nashua_south/Pages/default.aspx

BAE SYSTEMS PPAP SUBMISSION GUIDE- 94117-B45157 of 28 May 24, 2018

BAE SYSTEMS CONFIDENTIAL/PROPRIETARY INFORMATION

Revision HistoryRev Date Description

- 24 May 2018 Initial release per DCR DRB31135


Table of ContentsBAE Systems PPAP Guide......................................................................................................................................1

1.0 Purpose.....................................................................................................................................................4

2.0 Scope - When is PPAP Submission Required?...........................................................................................4

3.0 Reference Documents..............................................................................................................................4

4.0 Terms and Definitions.....................................................................................................................................5

5.0 Requirements for PPAP Submission:........................................................................................................8

5.1 Supplier PPAP Checklist............................................................................................................................9

5.2 Submission Method..................................................................................................................................9

5.3 Submission Status...................................................................................................................................10

5.4 Ongoing Requirements.......................................................................................................................10

6.0 Instructions for completing a PPAP Submission.....................................................................................10

6.1 Part Submission Warrant (PSW).........................................................................................................10

6.2 Design Records and Ballooned Drawings...........................................................................................12

6.3 Approved Engineering Change Documentation..................................................................................13

6.4 Customer Engineering Approvals.......................................................................................................13

6.5 Design Failure Mode and Effects Analysis (DFMEA).......................................................................14

6.6 Process Flow Diagrams......................................................................................................................15

6.7 Process Failure Mode Effects Analysis (PFMEA)..............................................................................16

6.8 Control Plan........................................................................................................................................18

6.9 Measurement System Analysis (MSA)..............................................................................................20

6.10 Dimensional Results...........................................................................................................................22

6.11 Material and Performance Test Results..............................................................................................25

6.12 Initial Process Study (Cpk, Ppk).........................................................................................................25

6.13 Qualified Laboratory Documentation.................................................................................................26

6.14 Sample Parts.......................................................................................................................................26

6.15 Checking Aids....................................................................................................................................27

6.16 Customer Specific Requirements........................................................................................................27



1.0 Purpose

The purpose of the PPAP Submission Guide is to assist the supplier to complete the various aspects of the Enhanced First Article (PPAP) as part of a process in accordance with AS9145.

The purpose of the Production Part Approval Process (PPAP) is:

A. To provide the evidence that all engineering, design record and specification requirements are properly understood and fulfilled by the manufacturing organization.

B. To demonstrate that the established manufacturing process has the potential to produce consistently conforming product which meets all requirements during an actual production run at the quoted production rate.

2.0 Scope - When is PPAP Submission Required?BAE may require a PPAP submission per purchase order requirements, when any of the following occur:

New parts, process or suppliers

A. New part or productB. New process or technologyC. New supplier

Changes to existing productA. Change to design including material, construction or component.B. New, additional or modified toolsC. Refurbishment of current toolsD. Production or equipment transfer to a different locationE. Change of sub supplier or material sourceF. New source of raw materialG. Change in production process or methodH. Product when tooling has been inactive for 12 months or greater.I. Major environmental impact affecting fit, form or function of the product.

3.0 Reference DocumentsSAE International AS9145™ – Requirements for Advanced Product Quality Planning and Production Part Approval ProcessSAE International AS9103 – Variation Management of Key CharacteristicsAIAG FMEA Manual- 4th EditionAIAG APQP ManualAIAG PPAP Manual- 4th Edition



AIAG SPC ManualAIAG MSA Manual-3d EditionIEEE 1490:2011 Adoption of the Project Management Institute (PMI(R)) Standard; A Guide to the Project Management Body of KnowledgeBAE Supplier Variation Request (SVR)

4.0 Terms and Definitions

Bill of Material (BOM):Total list of all components and materials contained in the design record of a product required to manufacture the product.

Containment: Recognition, identification and where possible, the segregation of the entire population affected by the condition of nonconformance. Containment includes raw material, stock inventory, kits, work-in-process, product in sell-off, finished goods inventory, goods in transit, and goods at BAE.

Control Plan:A written description of the systems for controlling production parts, materials and processes. Control plans identify the important characteristics and engineering specifications of the product and how they are controlled to assure quality of the product. The control plan should be linked to the process flow diagram and the process failures modes and effects analysis.

Critical Item (CI):Those items (e.g., functions, parts, characteristics, processes) having significant effect on the product realization and use of the product; including safety, performance, form, fit, function, producibility, service life, etc.; that require specific actions to ensure they are adequately managed. Examples include: safety CIs, fracture CIs, mission CIs, Key Characteristics (KCs), and maintenance tasks critical for safety (reference AS9103 standard).

Correction: Action taken to eliminate a detected nonconformity

Customer:The recipient of the supplier’s or organizations products or service.

Deliverables: Outputs completed as part of the APQP/PPAP process.

Design Failure Mode and Effects Analysis (DFMEA) An organized methodology used to assure that potential design risks are mitigated through mistake proofing and design/process enhancements. Potential risks are ranked and prioritized for improvement.



Design Records:The records of the engineering definition/specification, that fully define the product (system, part, component, or assembly), including physical or electronic/digital drawings, electronic/digital models, software, or other associated information. This includes records of authorized engineering changes (Approved via SVR) not yet incorporated into the released engineering definition/specification.

Design Risk Analysis:Analytical techniques used by the design responsible organization to identify, to the extent possible, potential failure modes related to product performance (i.e., fit, form, and function), durability, manufacturability, and cost.

Design ValidationThe assurance that a product, service, or system fulfills the needs of the customer and other identified stakeholders. It often involves acceptance with external customers (defined in IEEE 1490:2011). Relevant types of validation include: – Confirmation through the provision of objective evidence, that the requirements for a specific intended use or application have been fulfilled. Testing and/or analysis to ensure the product design conforms to defined user needs and/or requirements. Design validation follows successful design verification and may involve preproduction product (e.g., development, prototype) [reference AIAG Advanced Product Quality Planning and Control Plan].

Design VerificationTesting to assure that all design outputs meet the requirements of the design inputs with objective evidence that the specified product requirements have been fulfilled. Testing and/or analysis to ensure that all design outputs satisfy requirements may include activities such as: design review, performing alternate calculations, understanding tests and demonstrations, and review of design stage documents before release (reference AIAG Advanced Product Quality Planning and Control Plan).

Key Characteristic (KC)An attribute or feature whose variation has a significant influence on product fit, performance, service life, or producibility; that requires specific action for the purpose of controlling variation (reference AS9103 standard).

Measurement Systems Analysis (MSA)A study of the effects of selected elements (repeatability and reproducibility) of a measurement process on accuracy, precision, and uncertainty of measurement.

Nonconformance: The failure or potential failure of a characteristic to conform to the requirements specified in a contract, purchase order, drawing, specification or other approved product description. Potential/suspect non-conformances include improper handling, storage, transport, and exposure to out-of-tolerance environmental, test or process conditions.

Nonconforming Material: Any item, part, or product containing one or more nonconformance



Preliminary Capacity Assessment:An assessment performed early in the process planning and development phase to determine resources (e.g., people, equipment, facilities) necessary to produce product at the customer demand rate.

Preventive Action: Action to eliminate the cause of a potential nonconformity or other undesirable condition. If a nonconformance has not occurred, but an action is taken to proactively reduce the risk of a nonconformance, the action is preventive.

Process Capability: Comparing actual process performance with process specification limits using measure e.g.: Cpk, CP, Sigma Level and parts defective parts per million. Failure Mode and Effects Analysis (FMEA) An organized methodology used to assure that potential design and manufacturing risks are mitigated through mistake proofing and design/process enhancements. Potential risks are ranked and prioritized for improvement. Process Failure Mode and Effects Analysis (PFMEA) An organized methodology used to assure that potential manufacturing risks are mitigated through mistake proofing and design/process enhancements. Potential risks are ranked and prioritized for improvement.

Process Validation:Confirmation through physical demonstration that a process consistently produces a result or product fulfilling its predetermined specifications, including key product or process characteristics which are stable and capable at the desired level.

Production Process Verification (PPV): A review of the manufacturing process (e.g., equipment, operator training, manufacturing documentation, control plan, associated measurement tools) by a multi-disciplinary team to verify that the production processes are appropriately defined, documented, and ready for production.

Rework: A procedure applied to a nonconformance that will completely eliminate the nonconformance, and result in a characteristic that conforms completely to the drawing, specification or contractual requirement. SCAR: Supplier Corrective Action Request

Scrap: Nonconforming material that is not usable for its intended purpose that cannot be economically reworked.



Supplier:The entity or party that supplies product or services to a customer in accordance with contract requirements.

5.0 Requirements for PPAP Submission:

BAE Systems PPAP requirements are based on the existing AIAG "Production Part Approval Process" standard. Depending on the level of submission one or more of the following elements may be required:

A. Part Submission WarrantB. Samples of PartC. BAE Systems Approved Drawing of Revision level being submitted. The drawing must

also be labeled for cross - reference with dimensional layout.D. Dimensional LayoutE. Material AnalysisF. Design Verification Plan and Test Results, If ApplicableG. Approved Appearance Approval Form, If ApplicableH. Process Capability Studies with Ppk > 1.67 and data of Key Significant CharacteristicsI. Control PlanJ. Process FMEAK. Process Flow DiagramL. Gage Repeatability and Reproducibility Studies

Note: BAE Systems provides suggested templates of all forms for the PPAP submittal, however Supplier generated forms meeting the requirements of SAE INTERNATIONAL AS9145™ or AIAG may also be utilized.

Completion and submission of PPAP records conveys no additional data rights to BAE Systems than that defined in the respective Procurement Agreement.

The documents to be submitted are determined by which level of submission BAE Systems requests. If not specified the supplier must submit level 3, which is the BAE Systems default submission level.

Note: The PPAP Supplier Checklist found in the BAE PPAP forms package is interactive and will identify the forms required for each submittal after typing the submittal level on the top right hand box.

Those documents not submitted will be kept on file at the supplier's location and be readily available if needed. For more details about levels of submission or PPAP requirements the AIAG manual "Production Part Approval Process", is a good reference guide.



5.1 Supplier PPAP Checklist

The level of PPAP submission is determined by BAE Systems, the default submission will be PPAP level 3 unless specifically notified by BAE Systems.

To assist the Supplier to ensure all relevant documentation / evidence is submitted BAE Systems have developed a Supplier PPAP Checklist. This document can also be used by the Supplier to document concerns, comments and questions against the relevant PPAP elements. All concerns, comments and questions will be reviewed by BAE Systems during PPAP submission review and will take the appropriate actions.

Submission Level(Please Type 1-5) 3

BAE Part Number Part Description Supplier NameRevision Level BAE Purchasing Rep. Submission Date

Primary Manufacturing Site Purchasing Rep Phone # PPAP Due Date

Elem

ent

Ord

er

PPAP Requirements

Important: Submit your documents in this order. Le

vel 1

Leve

l 2

Leve

l 3

Leve

l 4

Leve

l 5

Incl

uded

1 Part Submission Warrant (PSW)

S S S S R

2Customer Approved Drawings of Revision Level being submitted.

R S S * R

3 Process Flow Diagrams R R S * R

4 Process FMEA R S S * R

5 Control Plan R R S * R

6 Measurement System Analysis Studies

R R S * R

PPAP Production Part Approval Process

Submission RequirementsSupplier Checklist

Comments/Concerns/Questions

Analogic Check Applicable Requirements

YES

YES

YES

YES

YES

YES

Please note that the checklist is to be included during the PPAP submission.

5.2 Submission Method

PPAPs ARE NOT TO BE SENT VIA REGULAR, UNSECURE EMAIL!!!

PPAPs are considered Technical Data and therefore must be controlled in accordance with contractual requirements specified in the special provisions of the Purchase Order / Subcontract or incorporated Terms and Conditions. Such requirements may include ITAR, Export Control, and Proprietary Information Agreements. Unclassified technical data shall be submitted through BAE Systems approved methods including but not necessarily limited to Secure File Transfer System (SFTS), Exostar, or physical mail.

Classified technical data shall be specially handled as specified in the Purchase Order or Subcontract.

Contact your BAE Systems procurement representative to confirm the approved transmittal method. BAE SYSTEMS CONFIDENTIAL/PROPRIETARY INFORMATION


5.3 Submission Status

The PPAP approval process will be carried out by BAE Systems. The PPAP submission will be reviewed and dispositioned one of the following ways:

APPROVED: A formal acceptance of the submission which has met all of the criteria set by BAE Systems.

REJECTED: The submission is not acceptable and does not meet the criteria set by BAE Systems.

INTERIM: An interim approval can be given if it is deemed by BAE Systems that product is useable. The interim status is a temporary approval for a specified time-frame which is determined by BAE Systems. The supplier must implement the required corrective actions and re-submit PPAP for full approval during this time frame. If a re-submission does not occur within the required time- frame the PPAP will be rejected.

5.4 Ongoing Requirements

BAE Systems reserves the right to request any information you have provided in any data or document in any element of approval, at any time, including after the approval has been granted.

6.0 Instructions for completing a PPAP Submission

6.1 Part Submission Warrant (PSW)

The purpose of the Part Submission Warrant (PSW) is to document the submission and the approval or rejection of purchased parts prior to production. BAE Systems has developed its own PSW document and is a required part of the PPAP submission.

Completing the Part Submission Warrant

The PSW form must be filled out and signed by the supplier.

The part number must match the Purchase Order issued by BAE Systems.

The correct revision level and submission level must be entered.

Any fields that do not apply to your submission should be filled in with “N/A” (Not Applicable).

It is important that the PSW is filled out correctly and contains accurate and legible information.



PPAP Level: (1-5) _____

Yes No N/A Yes No

Element # Target Date

Date

Date

PPAP Approval

I, the supplier, submit this PPAP Approval form as declaration of having met all applicable requirements of the AS9145 standard, except as noted above, including having implemented the requirements at the sub-tier level where applicable. I further certify that our production process meets all defined product delivery, engineering and quality requirements. I understand that the approval of this form by the customer does not release me from responsibility or liability for any non-conformances.

Name (clearly print and sign)

Note: "No" selections in Section 13a require an Action Plan item documented in Section 14 below

13a. PPAP Elements ProvidedCustomer Comments

1. Part Number:2. Part Name:3. Part Revision Level:4. Drawing Number5. Drawing Revision Level:

6. Additional Changes:7. Customer Purchasing Rep: 8. Purchase Order Number:

7. Initial Process Studies

Element Description1. Design Records2. Design Risk Analysis (e.g., DFMEA)3. Process Flow Diagram

16. Approval (Customer Use Only)

9. Organization Name: 10. Supplier Number

12. Submission

Supplier Information

4. Process FMEA5. Control Plan

11. Address (Street, City, State, Country, Postal Code):

13b. Customer PPAP Element Acceptance (Customer Use Only)

Reason:

6. Measurement System Analysis

8. Packaging, Preservation, and Labelling Approvals9. First Article Inspection Report (Including all material certs)

14. Action Plan

10. Customer Specific PPAP Requirements

15. Declaration

Email AddressTitle

Approved Interim Approval Rejected

Full SubmissionPartial Submission

Initial SubmissionResubmission



6.2 Design Records and Ballooned DrawingsThe purpose of designed records and ballooned drawings is to document and provide a copy of the formal print and to provide any additional engineering records for reference.

A ballooned drawing shows the parts or assemblies in a part print with numbered “balloons” that point to individual requirements of the part. The numbers on the ballooned drawing correlate with the numbers found on the Dimensional Data Sheet. A ballooned drawing must be submitted as part of the PPAP for every submission when dimensional results are required.



Completing the balloon drawing

All part requirements on the BAE Systems or Supplier print must be ballooned and numbered for reference and measurement. These may include:

A. Dimensions and tolerance of partsB. Electrical requirements (performance data, functional tests, etc)C. Visual features (color, texture, etc)D. Chemical characteristics (cure time, etc)E. Physical and mechanical properties (tensile strength, plating thickness, heat treat hardness, etc)F. Any other specified requirement that you have the capability to measure or that is described in

the print notes or reference specifications.

When dimensions are specified at multiple location on the drawing, the data for each location should be numbered separately.

6.3 Approved Engineering Change Documentation

This section is used to cover anything that is not addressed in a part print such a Supplier Variation Request for Deviation (SVR).

A. BAE Systems ECOs must be approved and not pending.B. Print change submissions must have current prints.C. All supplier initiated changes must have a copy of the approved BAE deviation form.

The Supplier Variation Request (SVR) must be approved by BAE Systems. The supplier must not proceed with the change until an approved SVR has been provided by BAE Systems.

6.4 Customer Engineering Approvals

The supplier submission is to include BAE Systems Engineering Approval documentation when requested. This will only be requested if the supplier has design authority of the parts/products.



6.5 Design Failure Mode and Effects Analysis (DFMEA)

Note: BAE Systems only requires a Design Failure Mode and Effects Analysis (DFMEA) to be included if the supplier has design authority.

A Design Failure Mode and Effects Analysis (DFMEA) shows evidence that potential failure modes and their associated risks have been addressed in order to eliminate or minimize their effects through product design changed and improvements.

The DFMEA is only required when the supplier has design authority of the product. The DFMEA must address all Critical Items (CI).

Severity, Occurrence and Detection ratings are used when performing FMEA activities. These rating scales must be compliant with the AIAG guidelines for FMEA.

Any potential failure mode not mitigated in the DFMEA should be included in the PFMEA.

When completing the FMEA an action plan must be established in line with the risk analysis table shown below:

Green area - no actions needed

Yellow area - no mandatory actions required, but corrective and preventative actions should be defined and communicated to BAE Systems to reduce the risk to both parties

Red area - mandatory corrective and preventative actions are required and shall be communicated to BAE Systems to reduce the risk to both parties



Completing the DFMEA

The DFMEA supports the design process by reducing the risk of failures. The DFMEA should be initiated before the design concept is finalized. Each item / function needs to be addressed. Any potential failure mode of the item / function should be defined as completely as possible. Recommended actions should be recorded.

Prevention is the preferred method to address the design failure mode. If prevention is not possible, then highlight detection controls. The DFMEA is not a standalone document and should also be linked to the PFMEA and Control Plans.

BAE Systems has developed a DFMEA form which can be utilized by suppliers. The form uses embedded ratings which will automatically produce the initial Risk Priority Number (RPN)

Severity x Occurrence x Detection = RPN

Example of BAE Systems DFMEA form –

FMEA numberItem Process Responsibility No. of Pages

Part Number Key dates Prepared byCore Team FMEA date (Orig.) Rev. Date

0 00 00 00 00 00 00 00 00 00 00 00 00 00 0

DESIGN FAILURE MODE ANALYSIS(DESIGN FMEA)

Potential Cause(s) / Mechanism(s) of

Failure

OCCUR

Current Process Controls Prevention

Current Process Controls Detection

DETEC

RPN

PROCESSFUNCTION Potential Failure

ModePotential Effect(s) of

Failure

SEV

CLASS

Recommended Action(s)

Responsibility & Target

Completion Date

Actions Results

Completion Date Actions Taken

SEV

OCC

DET

RPNREQUIREMENTS

6.6 Process Flow Diagrams

The purpose of Process Flow Diagrams is to document and clarify all the steps required in the manufacturing of a part. The primary process steps must match both the PFMEA and the Control Plan. Process flows must include the entire manufacturing process, receiving through shipping.

The Process Flow Diagram must also include key steps in the process and all offline activities (such as measurement, inspection and handling). The flow of the nonconforming material such as scrap parts, non-conforming parts and rework parts should also be included The supplier is not authorized to perform a repair on a part. Note: Suppliers may utilize their own Process Flow Diagram format.



6.7 Process Failure Mode Effects Analysis (PFMEA)

The Process Failure Mode Effects Analysis (PFMEA) is used to show evidence that any potential failure modes and risks have been addressed at the manufacturing level.

A PFMEA should be performed for every part, piece or equipment or process involved in manufacturing. The PFMEA is a cross functional activity and should not be conducted in isolation.

FMEA numberItem Process Responsibility No. of PagesPart Number Key dates Prepared by

Core Team FMEA date (Orig.) Rev. Date

0 00 00 00 00 00 00 0

Current Process Controls Prevention

Current Process Controls Detection

DETEC

RPN

Actions Results

Completion Date

Recommended Action(s)

Responsibility & Target Completion

Date

POTENTIAL FAILURE MODE ANALYSIS(PROCESS FMEA)

SEV

CLASS

Potential Cause(s) / Mechanism(s) of

Failure

OCCUR

PROCESSFUNCTION Potential Failure

ModePotential Effect(s) of

FailureREQUIREMENTS

When calculating the Risk Priority Number (RPN) for the PFMEA the following rating mechanism should be utilized to assess Severity, Occurrence, and Detection: (Severity x Occurrence x Detection = RPN)

Severity: An assessment of how serious the Failure Effect (due to the Failure Mode) is to the customer:



Occurrence: An assessment of the likelihood that a particular cause will happen and result in the Failure Mode:



Detection: An assessment of the likelihood that the current controls will detect the cause of the Failure Mode or the Failure Mode itself, should it occur, thus PREVENTING the Failure Effect from reachingyour customer. The customer in this case could be the next operation, subsequent operations, or the end user:

The PFMEA worksheet is a tool used to identify and show potential process risks associated with the manufacture of each part. It also highlights the controls at each stage of the manufacturing process; this detail should read across to the Control Plan.

6.8 Control Plan

A Control Plan defines the operation, processes, materials, equipment, methodologies and CIs for controlling variations in key product or process characteristics integral to the manufacturing process. Its purpose is to communicate the supplier’s decisions during the entire manufacturing process from material purchase through to final shipping. Specifically the control plan should address the following:

A. Methods of productionB. Identification of CI characteristicsC. Secondary or Outsourced Operations



D. Materials and their physical and chemical characteristicsE. Types of process equipment at each operationF. Types of test equipment used to measure each characteristicG. Specifications, sampling strategy, control and reaction methods used.H. Periodic conformance testing and product verification

All processes must have a control plan that defines all methods used for process control and complies with BAE Systems specified requirements. The control plan must clearly state each step in the process; the specification and all CI characteristics must be addressed for product and process. The Process Flow Diagram, PFMEA and Control Plan should be linked. Each major process step in the process flow diagram should correlate with PFMEA steps and there should be documented control plan actions for each of the steps.

Completing the Control Plan

This is a process whereby the Supplier simply documents all materials and processes involved in the manufacturing process from start to finish. The process flow diagram, ballooned drawing, and PFMEA all provide inputs to the Control Plan. All CIs identified as Process, First-Piece or Safety Related by the supplier or BAE Systems must be listed on the Control Plan.

A control plan should address all testing requirements, inspection and measurements that are required to verify product quality and conformity. The control plan should not be excessively dependent on visual inspection and should always target prevention techniques wherever possible.

The control plan should be developed in stages, from Prototype to Pre-Production and then into Production. The control plan is a “living” document and should be updated to reflect any changes to the manufacturing process and its controls.

BAE Systems has developed a Control Plan format which is available for suppliers to utilize if required.



Example of Control Plan document

Proto-Type Pre-Launch Production Key Contact / Phone Date of OriginationControl Plan Number

Part Number / Latest Revision Change Core Team Customer Engineering Approval / Date (If Required)

Part Name / Description Supplier / Plant Approval / Date (If Required) Customer Quality Approval / Date (If Required)

Supplier / Plant Supplier Code Other Approval / Date (If Required) Other Approval / Date (If Required)

Part / Process Name / Machine, Device, Characteristics SpecialProcess Operation Jig, Tools Char. Product / Process MeasurementNumber Description for Mfg. Class Specification / Tolerance Technique Size Freq.

BAE CONTROL PLAN

Date of Latest Revision - ref.

M/DD/YYM/DD/YY

Reaction PlanSample Control MethodNo. Product Process

Methods

6.9 Measurement System Analysis (MSA)

Measurement System Analysis (MSA) is a mathematical method of determining how much variation within the measurement process contributes to overall process variability. MSA is used to ensure the right measurement equipment is used to qualify production parts or processes.

BAE Systems requires an MSA study to be conducted on all measurement equipment that is used to accept or fail the product. This generally covers all measurement tools identified in the control plan.

A Gauge Repeatability and Reproducibility (GR&R) study is used to ensure that measurements taken in the manufacturing process and reasonably consistent regardless of how many times they are performed or how had performed them. It is important to select a sample size that encompasses the full range of parts.

BAE Systems recommends the following acceptance levels to be used:



1) % R&R should be 10% or less for CIs2) Marginal gauges (between 10% and 30%) should have an action plan to address and improve

the method of measurement.3) Gauges with R&R at 30% or more must not be used.

Statistical software, IE: Mini-tab, SPC Excel or equivalent may be utilized to conduct the measurement study. BAE Systems has also developed at GR&R worksheet for the suppliers to utilize. Instructions on how to complete the GR&R are included in the worksheet.

Example of GR&R worksheet

Hold Cursor Here for DirectionsPart Number: Comments:Part Revision:

Part Description: Nominal=Date Completed: + TOL=

Gage Name: -TOL =Gage Number:

Cal Date:

MeasurementsOPER1 OPER2 OPER3 OPER4 OPER5

Part trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range12345678910

X-bar X-bar X-bar X-bar X-bar

# persons R-bar R-bar R-bar R-bar R-bar

# parts (n) MaxR MaxR MaxR MaxR MaxR

# trial (m)LSL 0.000 USL 0.000 Max X-bar 0.0000 R-double bar =

a 0.00 Total Tolerance 0.0000 Min X-bar 0.0000 UCLR = R-double bar x D4

b 0.00 X-bar diff 0.0000 UCLR =D4 = 0.00 If R values in study are greater

than UCLR, these are statisticaloutlier and need evaluation

Repeatability Reproductibility GAGE R&REV=(R-double bar) x a Av=(X-bar diff x b)2-(EV)2/n/m)1/2 R&R = (EV2+AV2)1/2

EV= AV = R&R =

%EV = 100(EV/tolerance) %AV = 100(AV/tolerance) %R&R = 100(R&R/tolerance)

%EV = %AV = %R&R = 0.0%

GAUGE R&R TEMPLATE



6.10 Dimensional Results

The Dimensional Results are documented in the Dimensional Data Sheet referenced earlier in this document. The measurements in this form should correlate with your ballooned drawing from Item 6.2.

The parts used for dimensional data must be from production tooling / process and randomly sampled (if possible) from a run at production rate. The dimensional report must address all of the following:

A. All dimensionsB. All applicable notes on the drawingC. Any dimensions contained on reference prints

Note: The parts measured to obtain the dimensional results must be the same parts submitted for PPAP approval.

Completing the Dimensional Data Sheet

All dimensional requirements on the ballooned drawing must be listed on the dimensional data sheet. All sections of the dimensional data sheet must be filled out completely. The measurement method must be documented for every line item.

When a specific feature on the drawing has multiple requirements I.E. GD&T symbols the data must be recorded on individual line items with the dimensional data sheet.

Example: This call out would require 3 lines of separate data on the dimensional report.

Dimensional Data and all requirements should be documented via the standard BAE Systems FAI process per BAE Systems B25279:


1. Hole diameter (25+/-0.2)2. True Position (0.05 MMC on datum A,B,C)3. Cylindricity (0.1)


Note: Any concerns identified in the Dimensional Data should be brought to the attention of BAE Systems before submitting your PPAP.

6.11 Material and Performance Test Results

The purpose of this item is to ensure that the material is verified for its properties and acceptable performance is demonstrated.

Material test results should be provided in the form of a material composition report also called a Certificate of Analysis (CofA) from an accredited lab that confirms the material content meets a known standard, IE: Chemical and Physical Analysis Report.

It is the Supplier’s responsibility to confirm the composition of material not only at PPAP submission stage but also ongoing during the life of the product / project. This step should be placed into the FMEA process and the Control Plan.

A Certificate of Compliance (C of C) is acceptable during production shipping but is not acceptable during PPAP submission as the C of C will not give actual test results.

Performance Test Results should be acceptable, and meet the agreed upon specifications to be measured. Performance results may include data confirming any referenced specifications in the part print or specific testing required by BAE.

BAE Systems will communicate specific material, performance and testing requirements either in the part print, reference specifications or by a specific request prior to PPAP approval. It is the responsibility of the supplier to confirm the data and format of this requirement with the appropriate BAE Systems representative.

Test Data should not be submitted with the PPAP unless the purchase order calls out material clause 111 or 111T.

6.12 Initial Process Study (Cpk, Ppk)

The purpose of initial process studies (cp, Cpk, Pp, Ppk) is to determine if the production process is likely to manufacture product that will meet BAE Systems requirements. Initial process studies (capability) are highly recommended for all CIs.

There are two primary indexes used in determining process capability.

Cpk predicts future capability and should be used when developing new parts or revising specifications on a part. Cpk should also be used when materials, processes, manufacturing location, or equipment have changed or Material suppliers have changed.



Ppk indicates past performance. Use Ppk when you are a new supplier to BAE Systems but have already been manufacturing the part which BAE will purchase.

The capability study is to be performed on samples taken from an actual production run at the quoted production rates. The minimum acceptance capability for all CIs is 1.33 and 1.67 for all safety related CI’s.

The supplier can submit the Capability data on the format of their choice, and Mini-tab, SPC Excel or equivalent may be utilized.

6.13 Qualified Laboratory Documentation

The purpose of Qualified Laboratory Documentation is to ensure that the testing for PPAP has been done by a qualified lab. If your organization is performing testing or measurement internally or externally at an outside facility, then proof of Scope and accreditation is required.

Internal Labs located at Supplier

All suppliers that have testing or measurement performed on site must provide the following in this section of the PPAP submission:

A. Record / Scope that identifies the testing to be done and it must include:B. List of your personnel’s competency and training to perform the testing.C. List of all test equipment used in process and offline.D. List of methods and standards used to calibrate the equipment.

External Labs located offsite from the Supplier

If you are sending out for measurement and testing, you must ensure that you use an accredited lab and can provide proof of accreditation. BAE prefers external labs be accredited to known standards such as ISO 17025, ISO 10012:2004, or ANSI/NCSL Z540-1-1994.

A. Provide a copy of the lab company’s Third Party accreditation.B. Results must be on company letterhead and include the following:

The name of the lab Date of testing Standards used for testing

6.14 Sample Parts

Sample parts are to be included and are to be the actual samples measured in the dimensional analysis (Item 6.10). Sample parts are to be delivered with or before the PPAP submission.

The PPAP samples should be delivered with the label identifying them as PPAP Samples.



This is to avoid the PPAP sample parts being inadvertently misplaced or mixed up with production parts.

6.15 Checking Aids

The purpose of this item is to provide evidence that the checking aids used to verify product exist and have been properly validated.

There are many different types of checking aids. Examples of checking aids include but are not limited to certified check fixtures, un-certified check fixtures, templates, custom gauges and test equipment.

BAE requires all checking aids to be verified as repeatable through an MSA study. The MSA can be either attribute or variable depending on the type of checking aid in use.

6.16 Customer Specific Requirements

This item is to address BAE specific requirements during PPAP submission.

BAE will advise during the PPAP process on specific requirements as there may vary depending on the scope of the project / product being supplied. This item is also utilized to flow down requirements of BAE’s customers to ensure these elements are captured during PPAP submission.
