PPAP Policy

1. Customer driven design changes to a part BEFORE FAIR / PPAP (while it is in the process of qualification).

  1. Any costs incurred from the date of the initial PPAP request to the day of the design change notification will be the responsibility of the customer. This includes:
    i. All man-hours expended by Soucy Baron on the FAIR / PPAP at a rate of $125.00/hour.
    ii. Metal inserts purchased. (If they become unusable).
    iii. Raw materials purchased. (If they become unusable).
    iv. Samples produced. (If not purchased by customer).

2. Customer driven design change to a part AFTER PPAP is submitted.

  1. All new FAIR / PPAP costs will be the responsibility of the customer. This includes:
    i. All man-hours expended by Soucy Baron on the FAIR / PPAP at a rate of $125.00/hour.
    ii. Metal inserts purchased from the previous qualified version. (If they become unusable).
    iii. Raw materials purchased. (If they become unusable).
    iv. Samples produced from the previous qualified version. (If not purchased by customer).
  2. Exceptions:
    i. The design change generates a new part, which does not replace or reduce the EAU of the part currently produced and qualified.
    ii. The design change occurs at least 1 year after the PPAP submission, and at least 1 years’ worth of parts have been purchased per the quoted EAU (-10% acceptable) during a period of 1 year.

Definitions and examples

Design change:

A change in one of the following items, but not limited to:

  • Material
  • Geometry
  • Surface finish
  • Surface treatment
  • Manufacturing process that will modify the part’s performance
  • Tolerance tightening if this affects our process or our supplier’s process.

A design change results in a drawing change, but not all drawing changes are considered design changes. For example, an adjustment of tolerances to reflect the real condition of a part is not considered a design change.

NOTE: A part number change or a new part number issuance alone is not considered a design change, although it’s generally driven by a design change. The same applies if a new part number is created from a production tool that was built to produce another part. For example, a change in rubber compound creates a new part (one that does not replace the part made from the original compound).

**APQP / AIAG requirements:

  • A PPAP is composed of 18 different elements.
  • Most customers require a level III PPAP and often, a level II FAIR prior to PPAP.
  • A level III PPAP requires a significant production run which is defined as one hour to eight hours of production with a specific quantity to total a minimum of 300 consecutive parts. Variables such as the number of cavities in a tool and a part’s weight can also affect the requirements. At a minimum, a run must be one production batch of rubber, which is typically either 120 or 360 pounds depending on the internal mixer used for production.
  • When properties such as static and/or dynamic stiffness need to be measured, as is often the case with engine mounts, three batches of rubber from different production lots are required to establish reliable statistics.
  • On average, Soucy Baron is required to purchase three times the number of metal inserts needed for PPAP and APQP requirements to:
    -Meet our insert suppliers MOQ
    -Cover the FAIR requirements
    -Cover the APQP and PPAP requirements
    -Produce finished parts from this short run at and acceptable loss—parts that will be sold to customer at the part’s quoted production price. Putting this into perspective, it is not uncommon for us to order more than a thousand of each metal insert used in a part to ensure compliance with APQP and customers’ PPAP quality requirements.