PPAP Definition and Process

1. PPAP Definition and Process Shane Wilson & Karl Lu No More Defects……..Build Reliable Products…….Be The Reason

2. Open Discussion • How do you think that part can be approved completely? • What’s the current status? OEM v.s. Sub-tier • Can you provide part approval documents anytime as requested?

3. Table of Content • Open Discussion (done) • PPAP and AQP Introduction • Your Actions • Q & A

4. Part Examples • Examples are • Plastic parts • Sheet metal parts • Magnesium parts • Mechanical Sub-assemblies (including secondary operations) • Coatings over substrates (i.e. plastic, aluminum, magnesium) • Badges • Hinges • Coatings (liquid & powder paints, plating, etc.)

5. Definition & Elements Purpose Dell requires that both the part and process needs to be approved through the appropriate teams within Dell prior to start of mass production. There are 2 elements that need to be approved. These elements are the Production Part Approval Process (PPAP) and the Advanced Quality Planning (AQP) process. Elements Production Part Approval Process(referred to as PPAP) – owner is Dell Engineering Advanced Quality Planning(referred to as AQP) – owner is Dell Supplier Engineering & Quality

6. Submittal Requirements Within each one of these elements the below documents are required to be submitted for approval: PPAP • Sample Part (ran on the equipment intended for mass production) • Drawing • First Article Inspection (FAI) • Gage Reproducibility and Repeatability (GR&R) • Process Capability (Cpk) AQP • Process Flow Diagram • Process Management Plan (PMP) • Process Failure Mode and Effect Analysis (FMEA) • Process Work Instructions (reviewed during QPA for the assembly being qualified) ** PPAP and AQP’s can be submitted in Parallel or Series. AQP’s cannot be submitted until Engineering has approved the PPAP.

7. PPAP & AQP Quick View

8. Situations • The following situations identify common instances where the Part Qualification Process is utilized, however, its use is not exclusive of other possible scenarios. • New Part or New Tool • Engineering Changes • Tooling Transfer, Replacement, Refurbishment • Correction of Discrepancy • Change to Optional material • Change in Part Processing/method of manufacture • Sub-supplier or Material Source Change

9. PPAP Documents Examples of PPAP documents in Agile Mechanical PPAP Documents and Work Instructions -p/n ENG0000010 (PPAP worksheet) -p/n ENG0000011 (PPAP worksheet work instructions) -p/n ENG0000012 (Mechanical Part Qualification Process) -p/n ENG0000121 (Cable Part Qualification Process) Paint Supplier and Applicator PPAP Documents and Work Instructions -p/n ENG0000229 Paint Applicator PPAP Work Instruction -p/n ENG0000230 Paint Applicator Report - p/n ENG0000231 Paint Supplier PPAP Work Instruction -p/n ENG0000232 Paint Supplier Report

10. AQP Documents AQP documents are loaded in Value Chain Cor.40.WWP.SQ.0257.Mechanical AQP AQP consist of: Process Flow Process Management Plan Failure Mode Effect Analysis (FMEA)

11. PPAP & AQP Flowcharts

12. Requirements Requirement #1: Sub-tier should provide AQP Doc. To OEM SQE and get OEM SQE’s approval (as previous requested situation) Owner: Sub-tier & OEM SQE Requirement #2: Any deviation from requirement#1, OEM SQE should escalate Dell responsible SEQ. Owner: OEM SQE Requirement #3: Both Sub-tier and OEM should maintain all AQP doc. And are able to deliver anytime as requested. Owner: Sub-tier & OEM SQE

13. Any Question?

14. Thank you!