2221 SUPPLIER PPAP Training Master Overview …

1 Cooper IndustriesSupplier ppap Training ( SUPPLIER )Revision 07/28/08 Division ppap Training AgendaPlace Your Divisions Agenda here! ppap Training 3 Primary Training Sessions AvailableSessionsDurationSuggested StaffFocus Overview ppap Training1 hourManagementBasic Overview of theManufacturingCooper ppap Standard Internal StaffTraining2 HoursPurchasingMore In depth Training Internal StaffTraining2 HoursPurchasingMore In depth trainingEngineering& includes reviewerchecklists & tips. SUPPLIER ppap Training 3-4 HourSuppliersStill more in depth withQuality focus on key topics andparticipation exercises Benefits of ppap Submissions ppap provides for many benefits. Forces formal part conformance and approval Ensures formal quality planning Helps to maintain design integrity Identifies issues early for resolution Identifies issues early for resolution Keeps suppliers honest Reduces warranty charges and prevents costs of poor quality Assists with managing SUPPLIER changesgg ppg Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfactionPPAP provides many benefits for all areas of the businessPPAP provides many benefits for all areas of the Training Objectives What is the Purposeof ppap ?

2 When is ppap Required? What are the Elements of the submission? How are the Levelsof ppap applied? Details on successful ppap submission to Cooper is the ppap standard? Production Part Approval Process Standard for submitting to the customer for part approval Standard for submitting to the customer for part approval. AIAG 4thedition is most recent in March 2006 Developed by AIAG originally in 1993 for the Automotive Industry with input from the big three OEM sthree OEM s. Outlines customer requirements that must be delivered and approved prior to production qppppof product. C ppap ittt d td ditt i lli( tl) Cooper s ppap requirements are targeted towards direct material suppliers (external)Whatis the purpose of ppap Submissions? ppap s purpose is: To provide the evidence that all customer engineering design record and specification requirements are properly understood by the manufacturing organization.

3 To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production runat the quoted production ratequoted production manages change and ensures product conformance!Significant Production Run ppap data must be submitted from a significant production run , which is identified by AIAGas 300 consecutive pieces sampled randomly (unless otherwise agreed upon by theAIAGas 300 consecutive pieces sampled randomly (unless otherwise agreed upon by the customer and SUPPLIER ). 300 pieces from productionnot prototype Production equipment and tooling Production employees Production rateAll data reflects the actual production process to be used at start-up!pppWhen is ppap typically required? If the process or the part changes it requires ppap submission New part New part Revised part SUPPLIER related changes Changes in tooling, equipment or inspectiongg,qp p Change in the manufacturing process or method If you are unsure contact your Quality or SUPPLIER Quality Representative If you are unsure contact your Quality or SUPPLIER Quality Representative.)

4 New Parts:Typically will advise at time of business award(New Parts) Reference the Cooper ppap Quick Reference Changes:Review at the time of a proposed changegppg Reference the SUPPLIER Change Request FormAny significant change to product or process! ppap RequirementsWhat are the actual requirements?The Basics of PPAPAIAGS ubmission requirements are called ElementsPSWW hich element is required is determined by the submission LevelPSWDon t be intimidated by all of the acronymsPPAP Elements (Requirements)(AIAG) 4thEdition ppap 1. Design Records 2Ei i ChDtCooper Requirements 2Di R d 2. Engineering Change Documents 3. Customer Engineering Approval, if required 4. Design Failure Modes & Effects Analysis (DFMEA) 5. Process Flow Diagram 6. Process Failure Modes & Effects Analysis (PFMEA) 7 Control Plan 2.

5 Design Records 3. Engineering Change Documents 4. Customer Engineering Approval 5 DFMEA 6. Process Flow Diagram 7 PFMEA 7. Control Plan 8. Measurement Systems Analysis (MSA) 9. Dimensional Results 10. Material, Performance Results 11. Initial Process Study 12. Qualified Laboratory Documentation 7. PFMEA 8. Control Plan 9. Measurement Systems Analysis (MSA) 10. Dimensional Results 11. Material, Performance Results 12. Initial Process Study 13. Appearance Approval Report (AAR) 14. Sample Product 15. Master Sample 16. Checking Aids 17. Customer-Specific Requirements 18 Part Submission Warrant(PSW)y 13. Qualified Laboratory Documentation 14. Appearance Approval Report (AAR) 15. Sample Product 16. Master Sample 17. Checking Aids 18 CSifiRit 18. Part Submission Warrant (PSW) 18. Cooper-Specific Requirements Tooling information Form Packaging Form Inspection Plan (ASC Only) Specification Deviation SUPPLIER ppap Worksheet 1.

6 Part Submission Warrant (PSW) SUPPLIER ppap WorksheetCooper will require most of these and Cooper specific documents . ppap Submission LevelsCooper Requirements 1. Part Submission Warrant (PSW) 2. Design Records 3 Engineering Change DocumentsLevel 1 Level 2 Level 3 Level 4 Level 5 ARARAR FullPartialWarrant OnlyAs Requested Full On Site 3. Engineering Change Documents 4. Customer Engineering Approval 5 DFMEA 6. Process Flow Diagram 7. PFMEA 8. Control Plan 9. Measurement Systems Analysis (MSA) ARARARARARARAR yy() 10. Dimensional Results 11. Material, Performance Results 12. Initial Process Study 13. Qualified Laboratory Documentation 14. Appearance Approval Report (AAR) 15. Sample Product 16 M tSl ARARARARARARAR 16. Master Sample 17. Checking Aids 18. Customer-Specific Requirements Tooling information Form Packaging Form Inspection Plan (ASC Only) Specification Deviation ARARARARARARAR SUPPLIER ppap Worksheet AR Shall Submit Shall Retain Level 3 will be the default submission of Due Diligence through PPAPC ooper Requirements 2.

7 Design Records 1. Part Submission Warrant (PSW) 2. Design RecordsRequirementsCTQsElement LinksCritical Systems 3. Engineering Change Documents 4. Customer Engineering Approval 5 DFMEA 6. Process Flow Diagram 7. PFMEA 8 Control PlanCTQs 5 DFMEAMore Robust Design 7. PFMEAR obust Process 8. Control Plan 9. Measurement Systems Analysis (MSA) 10. Dimensional Results 11. Material, Performance Results 12. Initial Process Study 13. Qualified Laboratory Documentation 8. Control PlanDevelop Process Control 9. MSAC onfirm Measurement 13. Qualified Laboratory Documentation 14. Appearance Approval Report (AAR) 15. Sample Product 16. Master Sample 17. Checking Aids 18. Cooper-Specific Requirements 12. Initial Process StudyVerify and improve capability 18 Cooper SpecificCustomer Requirements Tooling information Form Packaging Form Inspection Plan (ASC Only) Specification Deviation SUPPLIER ppap Worksheet 18.

8 Cooper SpecificCustomer RequirementsSubmitDiligence is critical because elements relate and build on each otherMore onLevel Application ppap Standard is a Framework Standard At the customer s discretion (Cooper) to define the picture within the frameLevel 1 Warrant only and Appearance Approval Report as requested submitted to the to: "Non-critical" parts, "non critical" raw/bulk material or catalog/ commodity parts for electrical applications and re-certification of existing parts previously approved by Cooper at Levels are defined by AIAG and the Customer AIAG has pre-determined the general application. Customer has discretion to apply the specific 2electrical applications and re-certification of existing parts previously approved by Cooper at levels 3, 4 or 5. Also used for Self CertificationWarrant with product samples and limited supporting data submitted to the to:Critical Bulk products such as Plastic/Paint/Chemicals, critical fasteners, simple tilhil iil llhil itdt tfftiffitLevel 3material changes, simple revision level only changes or simple print updates not affecting form-fit-function.

9 This level can also be applied to low and medium risk parts within a product with product samples and complete supporting data submitted to Cooper Industries Submission LevelApplied to: New parts on Cooper programs. Level 4ppppppgChanges affecting form-fit-function, reliability, or performance. All product resourced to new suppliers, serial production parts, existing high risk parts undergoing a part number and other requirements as defined by the level is reserved for special applications onlyApplied to: This level can only be applied with prior approval from theLevel 5applications to: This level can only be applied with prior approval from the designated divisional Cooper Quality ppap with product samples and complete supporting data reviewed at the SUPPLIER 's manufacturing to:On site review as requested by each Cooper Checklist for PPAPC ooper has both a SUPPLIER Checklist and a Internal Quick ReferenceWhenis notification of change required?

10 Suppliers are required to receive formal approval for changes. Cooper has a formal document called the SUPPLIER Change Requestto be used by suppliers for ALLpotential changes. The SCR form allows for proper disposition of ppap . Must be approved by both Cooper purchasing and quality. Can also be used for SUPPLIER changes that are driven internally! Includes recommendations for the ppap LevelSuppliers are required to notify Cooper of ANY intent to change!Suppliers are required to notify Cooper of ANY intent to change!Whenis notification of change required?SCR defines the type of change that requires notifying CooperPPAP RequirementsCompleting the ppap SubmissionElectronic Submission Requirements Cooper Industries requires that all PPAPs be submitted electronically. Preferred Method: Use a designated FTTP site for downloading.