In the automotive industry, the Part Submission Warrant (PSW) plays a critical role in the Production Part Approval Process (PPAP). PPAP is a standardized process that automotive manufacturers and suppliers use to ensure that all parts and components meet specifications.

PSWs summarize key information about submitted parts in a detailed manner. It includes the materials used, the manufacturing process, and the testing procedure. Additionally, it contains information regarding the manufacturing facility and the production team.

PPAP submissions are represented by the Part Submission Warrant (PSW). In the absence of a customer statement, a PSW is required for all part numbers.

There are several things included in the PSW:

• Describe the reason for submission (i.e., initial submission, engineering changes, parts produced at another location, change in part processing, material source change, annual revalidation, etc.).
• Submission level to the customer (Level 1 to Level 5)
• Declaration of part conformity to customer requirements.
• Authorized supplier person signature along with contact information.
• An area for the customer to indicate the disposition of the PPAP.

PSWs are typically reviewed and approved by both suppliers and customers in the automotive industry. It could be the automotive manufacturer or another supplier in the supply chain. The PSW ensures that the submitted parts meet the specifications and expectations of the customer.

PSW ensures quality and consistency throughout the supply chain as part of the PPAP process. Before full-scale production begins, any potential issues or concerns related to the parts being produced can be addressed. As a result, it can be used as a reference for future issues. In the automotive industry, Part Submission Warrants play a crucial role in ensuring that all stakeholders are aware of what parts are being manufactured. Additionally, it ensures that they meet quality standards.

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PPAP Process Model with feedback:

Initial Process Studies:

Initial Process Studies is the application of statistical techniques to determine whether the output of the process confirms to the products of service designs.

A process is in control if:

1. No sample points outside limits.
2. Most points near process average.
3. About equal number of points above and below centerline.
4. Points appears randomly distributed.

Initial process Studies:

• Purpose is to determine if production process is likely to produce a product that meet customer requirements
• Initial process capability and performance to be determined for all special characteristics designated by customer or organization
• Customer concurrence to be obtained on Indices for estimating process capability prior to submission ( Cpk, Ppk).
• Initial studies focus on variables and not attribute data
• May be replaced by long term historical data from similar process- customer concurrence needed
• For bulk material 鈥� customer agreement required
• Index>1.67-acceptable
• For Index between 1.67 and 1.33, customer agreement needed
• Index <1.33 currently not acceptable.
• Initial process capability acceptance criteria is only one of a number of requirements that leads to

Process Capability:

Calculate the appropriate statistical metrics in order to determine how the 鈥淰oice of the Process鈥� compares to the 鈥淰oice of the Customer.鈥�

Capability Indices:

• Cp – Relates short term (within subgroup) standard deviation to tolerance. Sometimes called 鈥淓ntitlement,鈥� meaning it is the best the current process can do, if centered
• Cpk – Relates short-term mean & short term (within subgroup) standard deviation to tolerance. Only tells you about the nearest spec limit; doesn鈥檛 tell anything about the other side
• Pp- Relates long term (overall) standard deviation to tolerance
• Ppk – Relates mean & long term (overall) standard deviation to tolerance
• Only tells you about the nearest spec limit; does not tell anything about the other side

Difference between Cp & Cpk:

• Cp 鈥� Determines capability of producing to specification
• Cpk 鈥� Same as Cp, but also measures how centered the process is
• It is important to look at both!

Cpk predicts capability

• Based on short term within subgroup variation
• Does not include the effect of process variability between subgroups

Cpk should be used when:

• Developing new parts
• Revising specifications on a part
• Materials, processes, manufacturing location, or equipment have significantly changed
• Material suppliers have changed (include certificate of analysis)

Ppk indicates past performance:

• Based on long term total variation
• Unlike Cpk, Ppk is not limited to variation within subgroups
• However, Ppk cannot isolate within subgroup variation from between subgroup variation
• When calculated from the same data set, Cpk and Ppk can be compared to analyze the sources of process variation

Ppk should be used when:

• The supplier is new to customer , but has already been manufacturing a part
• The supplier is existing, but has produced a number of nonconforming parts

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