Group Standard Customer PPAP

[Virtual Presenter] Speaker: Welcome to the eLearning for the Group Standard Customer Production Part Approval Process, PPAP [speak: “pe-pepp”. DO NOT SPEAK: P-P-A-P!!!].

[Audio] Speaker: This eLearning is structured into six part: 1. Mission and Scope, 2. Approach, 3. Contents, 4. Process Flow, 5. Deliverables, 6. Further Information..

[Audio] Speaker: The first topic we will talk about in this eLearning is the mission of the Group Standard Customer PPAP. There are five main purposes of the Group Standard. Animation 1 appears Speaker: First purpose is to ensure a sufficient level of quality which every PPAP at Continental should have. Animation 2 appears Speaker: Second is to set a maximum of content. For example, if we say to the customer, that the customer cannot have the complete FMEA from us, that the customer can come to us, have a look into it, and that we can provide an evidence but not the complete document, then with the Group Standard Customer PPAP we have a well-founded basis for negotiation with the customer. Animation 3 appears Speaker: The third purpose is to harmonize the PPAP activities and to focus them on the business purposes of the PPAP. That means to reduce that Non-Conformance Costs by having a complete and archived PPAP documentation available in case of customer claims. Animation 4 appears Speaker: Fourth is to represent Continental's self-conceptions how to execute a PPAP. Animation 5 appears Speaker: The fifth purpose is to ensure higher customer satisfaction by Quality First..

[Audio] Animation 1 appears Speaker: When creating the Group Standard Customer PPAP the given target was to develop a Standard for the Customer PPAP. Animation 2 appears Speaker: Why? The starting situation was, that there were various PPAP procedures for customer products, some on plant level, some on BU level, but there was no consistent approach. Animation 3 appears Speaker: The future situation will be that there is one harmonized PPAP Standard. This standard is adjustable for specific customer requirements and includes the definition of the proceeding and the responsibilities as well as of all related PPAP subjects, like PPAP planning, readiness for PPAP, Run at Rate and archiving. And for Automotive Technologies there is a PPAP SAP Tool which is integrated in "SPIRIT". SPIRIT is a big SAP harmonization program which is currently rolled-out at Automotive. The PPAP SAP Tool has been already rolled out and after the go life of SPIRIT, there will be an additional interface to the local ERP systems..

[Audio] Speaker: Let's have a look on the scope of the Group Standard Customer PPAP. Animation 1 appears Speaker: In scope are PPAPs that we are doing towards the customers – for products of the Automotive Industry. Animation 2 appears Speaker: Out of scope are products for other industries. Animation 3 appears Speaker: Out of scope are also PPAPs that we are receiving from external suppliers because there are already standardized rules existing. Animation 4 appears Speaker: But in scope are PPAPs that we are receiving from internal suppliers. So, for the Internal Business – also called Intercompany Business – the same rules apply as for Customer PPAP..

[Audio] Speaker: After we have completed the first topic of "Mission and Scope", we can move on to the next topic the "Approach"..

[Audio] Speaker: Let's talk about the basis first. The Group Standard Customer PPAP is based on 1. Legal Requirements, 2. Requirements from Norms and Standards and 3. Customer Requirements. Animation 1 appears Speaker: Furthermore, it is based on common industry-standards for product approval like VDA PPA and AIAG PPAP as well as on requirements from Continental side. [Pause] When we developed this Standard – how did we do this in concrete? Animation 2 appears Speaker: We had a look at what deliverables are requested, e.g., by VDA PPA and what deliverables are requested by, e.g., AIAG PPAP. Animation 3 appears Speaker: Then we have created a mapping that shows what deliverables are the same. For example, VDA calls item 5.3 "Test Equipment for Product and Production Process" and AIAG calls item 16 "Checking Aids". Animation 4 appears Speaker: That means if we have e.g., deliverable number 26 "Checking Aids" on the Continental side, we can easily assign it to the equivalents in the different PPAP standards. Animation 5 appears Speaker: We checked every deliverable step by step and, if it makes sense, we integrated it into the Group Standard Customer PPAP. This is marked here with "Yes" or "No". Animation 6 appears Speaker: The mapping shows as well which deliverables are required only from VDA side..

[Audio] Speaker: Let's continue with the basis… Animation 1 appears Speaker: …and the mapping of the PPAP standards. Animation 2 appears Speaker: Here we can see more deliverables that are required only from VDA side. Animation 3 appears Speaker: There are also a few deliverables that are only required from Continental side because they are a kind of an insurance in case of customer claims. [Pause] Finally, we came up with 32 Core Customer PPAP Deliverables which – if they are technical applicable – must be part of every PPAP, it doesn't matter if they are requested by customer or not..

[Audio] Speaker: Now, let's come to the contents. The Group Standard Customer PPAP consists of the main body and the Annexes..

[Audio] Animation 1 appears Speaker: Here we can see the main body of the Standard. It is structured into: Animation 2 appears Speaker: Scope Animation 3 appears Speaker: Core Elements Animation 4 appears Speaker: and Application [Pause] The Core Elements contain Animation 5 appears Speaker: the Proceeding Animation 6 appears Speaker: the Deliverables Animation 7 appears Speaker: Task and Responsibilities Animation 8 appears Speaker: Internal Business Animation 9 appears Speaker: Archiving Animation 10 appears Speaker: and Special Requirements..

[Audio] Speaker: In the previous slide we already talked about the scope. So, let's come to the Core Elements and go directly into the "Continental Customer PPAP Deliverables". Animation 1, 2 and 3 appear Speaker: On the slides with the mappings of VDA and AIAG we have identified the 32 Core Customer PPAP Deliverables. These 32 Core Customer PPAP Deliverables are sorted into five groups: The General Deliverables, The Deliverables of the Product [emphasis] Design and Development, The Deliverables of the Production Process [emphasis] Design and Development, the Deliverables of the Product [emphasis] Validation and the Deliverables of the Production Process [emphasis] Validation. Animation 4 appears Speaker: On top of that , there may be Project-specific PPAP Deliverables due to additional Customer Requirements or due to additional Internal Requirements. [Pause] This image summarizes the flow of the deliverables. We can understand this image as a shelf which is open to both sides and every department must provide the deliverables that they have worked out. That means, every department must provide its deliverables for example to the Deliverable Folder Structure, must release the deliverables in WISE or must upload them to the PPAP SAP Tool. Animation 5 and 6 appear Speaker: For example, on the left hand of this shelf there is the engineer which uploads the customer drawing to the PPAP SAP Tool. On the right side there is the responsible person for Customer PPAP. That is the Quality Manager for Product and Production (QMPP) who must do the final formal check of all deliverables. Based on the rules for customer PPAP, the QMPP must handover the PPAP Package to the Customer..

[Audio] Animation 1 and 2 appear Speaker: As we have already learned when we talked about the scope, the same rules apply for Customer PPAP and for Internal Business – which is often also called "Intercompany Business". For example, one plant of Continental is producing a sensor and delivering it to another plant of Continental where this sensor is used as a component and assembled within the finished product that is delivered to the OEM. Animation 3 appears Speaker: That means that the internal supplier must execute the 32 core customer PPAP deliverables. The difference is that for the submission it is generally sufficient that only the PSW cover sheet is submitted from the internal supplier to the internal customer. Doing this, the Continental standard template for PSW (Annex 6) must be used. [Pause] In case that the internal customer needs more documents, because for example the OEM wants to see some test results, then this has to be aligned between the internal supplier and the internal customer..

[Audio] Speaker: After the PPAP deliverables have been created, they must be documented and archived. The following rules apply for the archiving of PPAP documents. Animation 1 appears Speaker: The rule is that all documents for each PPAP must be archived. All PPAPs must be collected over the life cycle of a part and archived including all new parts resulting from changes. [Pause] On the top of the page, we can see the reference points: Start of Production (SOP), End of Production (EOP), End of Delivery (EOD) and Deletion. Animation 2 appears Speaker: The first PPAP with the material number 4711 shows the initial PPAP. It must be archived after the reference point End of Delivery. Animation 3 appears Speaker: In this example the second PPAP is a PPAP due to a change where we can keep the same material number. It must be also archived after the reference point End of Delivery. Animation 4, 5 and 6 appear Speaker: The following PPAPs with the material numbers 4712 to 4714 show PPAPs due to changes where the material number must be changed. The rule is that for each PPAP due to a change a separate PPAP Folder must be created in the PPAP SAP Tool. But we only need to upload the documents that have changed. And in the tool, we can make a reference to the previous PPAP folder so that – in the end – the complete documentation will be archived in one PPAP package together. Animation 7 appears Speaker: The retention time of PPAP documents for all parts is 15 years starting from the reference point "end of delivery" (EOD). Such a long archiving time cannot be ensured by the Shared Drives and SharePoints, and also WISE does not have an archiving function. The only tool that can ensure such long archiving times is SAP. That is why all PPAP documents must be uploaded to the PPAP SAP Tool. There are three conditions that must be fulfilled in order to enable that the archiving processes will be started in the background: 1. The documents must be uploaded as PDF, 2. the deliverable folder must be in the status released and 3. the PPAP Folder must be in the status "Approved". [Pause] Regarding the archiving rules for the PPAP Master Sample, the retention time must be aligned with the customer. If there is a product that belongs to one of the categories of ASIL A-D (Automotive Safety Integrity Level), the alignment with the customer must include a minimum retention time of end of delivery + 15 years. The storage modalities must be defined in the PPAP Plan..

[Audio] Animation 1 and 2 appear Speaker: Let's come to the Annexes of the Standard. Annex 1, 2 and 3 are describing the Tasks and Responsibilities for Customer PPAP proceeding and for the deliverables. The content of Annex 1, 2 and 3 is the same, except for the last column. In the last column is listed which function or role must execute the task or provide the deliverable. For Automotive the Annex 2 is relevant and for Tires the Annex 3. The Annex 1 where no functions and roles are listed is used by ContiTech because there is not such a concept of defined roles on Business Area level at ContiTech as it is existing at Automotive. Animation 3 appears Speaker: In Annex 1-3 for each proceeding activity or process step, the related tasks and the responsible functions or roles are defined. The tasks are mapped to the standard project phases of Continental. Furthermore, for all 32 Core Customer PPAP Deliverables an explanation about the content, the definition of the submission restrictions and the responsible functions or roles are defined in Annex 1-3..

[Audio] Animation 1 and 2 appear Speaker: Annex 4 is the PPAP Trigger Matrix. It will be applied if there is a change request after the start of the series production. The PPAP Trigger Matrix helps us to decide whether we must execute a new customer PPAP, whether we can realize the change and just inform the customer about the change, or whether we can perform the change without involving the customer. The application of Continental's PPAP Trigger Matrix must be aligned with the customer in the Customer PPAP Plan, and this brings us directly to the next slide….

[Audio] Animation 1, 2 and 3 appear Speaker: …that shows the Annex 5a – the Customer PPAP Plan. Animation 4 appears Speaker: The target of the Customer PPAP Plan is to align with the customer in the early phase of the project the requirements of the PPAP Package. If the customer does not request to use its own template for the Customer PPAP Plan, Continental's template of Annex 5a must be used..

[Audio] Animations 1 and 2 appear Speaker: The Customer PPAP Plan that we saw on the last slide is an external document that can be shared with the customer. The Annex 5b – the Project PPAP Plan – that we can see now is an internal document that is for internal use only. Animation 3 appears Speaker: In the Project PPAP Plan we define for each deliverable and for each process step who is responsible and what is the due date. So, the names of the project team members and the dates of the gates will be entered here. The Project PPAP Plan shows which person must provide the PPAP deliverables to the PPAP SAP Tool until when..

[Audio] Animation 1 appears Speaker: Annex 6 is the Part Submission Warrant, PSW, which is the cover sheet of the PPAP package. This cover sheet contain all main information about the PPAP package, such as product, material number, and a list of the attached documents. Animation 2 appears Speaker: If the customer does not require any specific template, we must use Continental's template. It also must be used for all intercompany business..

[Audio] Speaker: The next topic that we will discuss in this eLearning is Process Flow..

[Audio] Speaker: The Continental Customer PPAP Proceeding consists of four main phases: Animation 1 appears Speaker: The first phase is the PPAP Start with PPAP Initiation and the Planning of the PPAP. Animation 2 appears Speaker: Then there is the PPAP Validation where we check if we are ready for the PPAP Sample Production, then the execution of the PPAP Sample Production, and the Product and Production Process Validation. Animation 3 appears Speaker: Third phase is the Series Production Approval, where we verify the PPAP readiness for the Customer PPAP and Run@Rate [speak: run at rate] and the execution of the Customer PPAP and Run@Rate. Animation 4 appears Speaker: The phase four is the Archiving which runs in parallel. Animation 5 appears There is also a detailed process flow chart available and a separate eLearning which is describing all the process steps in the process flow chart..

[Audio] Speaker: Regarding the workflow, I would like to draw your attention on the main steps. Animation 1 appears Speaker: In the first step, the Project Manager (PM) must initiate the creation of the PPAP Folder and must provide the Project ID from ePSR that is often called "DG-number". Animation 2 appears Speaker: The second step is to create the PPAP Folder in the PPAP SAP Tool and to enter the project data, which is a task for the Quality Manager for Product in Production (QMPP). Animation 3 appears Speaker: Next step is to align the PPAP requirements with the customer in the Customer PPAP Plan. This is a task for the PM. Animation 4 appears Speaker: Fourth step is to assign to the team members in the Project PPAP Plan which person has to provide which deliverable until when. This is also a task for the PM. Animation 5 appears Speaker: The Project PPAP Plan must be uploaded to the PPAP SAP Tool before G40..

[Audio] Speaker: Let's continue to go through the workflow of the PPAP proceeding. Animation 1 appears Speaker: The next step is that each function or role uploads the PPAP deliverables to PPAP SAP Tool as defined in the Project PPAP Plan according to the Annex 2 for Automotive Technologies. The person which is providing deliverable is responsible that the deliverable fulfills the requirements content-wise. Animation 2 appears Speaker: In the end, the responsible person for Customer PPAP must do the final formal check of all deliverables and handover the PPAP Package to the customer. This is the responsibility of the QMPP. Animation 3 appears Speaker: The PSW must be approved by the customer and PPAP Folder must be changed to the status "approved" in the PPAP SAP Tool before G80..

[Audio] Speaker: We have just learned that the PPAP deliverables are provided by the different functions or roles. This bring us directly to our next chapter: Chapter 5 "Deliverables"..

[Audio] Animation 1 appears Speaker: Customer PPAP is teamwork, and all relevant roles and functions provide the documents that they have worked out to the PPAP SAP Tool. It is described in several eLearnings about the PPAP SAP Tool how documents can be provided to the PPAP SAP Tool via WISE, OneDrive, SharePoint or Teams. In this image we can see the project core team in orange and the plant team in grew. The roles that provide the documents for Customer PPAP are: Animation 2 appears Speaker: the Project Manager, PM, Animation 3 appears Speaker: the Quality Manager for Product in Production, QMPP, Animation 4 appears Speaker: the Quality Manager in Project, QMP, Animation 5 appears Speaker: the New Product Launch Manager, NPL M, Animation 6 appears Speaker: the Industrialization Engineer, IE, Animation 7 appears Speaker: the Technical Project Leader, TPL. Animation 8 appears Speaker: and the Supply Chain Manager, SCM Plant..

[Audio] Speaker: This was the eLearning about the Customer PPAP. Thank you for your attention!.