Delivering a PPAP Level 3 dossier in 6 weeks for a Tier-1 bracket launch

The situation

A Tier-1 supplier needed a die-cast bracket launched against a compressed programme, and had been burned before by suppliers who submitted incomplete PPAP dossiers that triggered customer rejections late in the launch.

What was done

• 1The requirement was re-specified against a measurable acceptance test before any price was discussed — in this case days from purchase order to approved ppap warrant measured on incoming goods, not on a supplier’s own paperwork.
• 2Process control was changed to hold that measurement: process at High-pressure die casting, 800 t machine, material at AlSi10Mg (EN AC-43000), conforming to DIN EN 1706.
• 3Evidence was tied to each lot so the buyer could verify the claim rather than trust it. That is why the programme ran 130 days: the first 7 lots were used to prove stability before volume was released.

Evidence you can ask to see

Signed PSW, dimensional layout inspection report, MSA study, process capability indices, tool history record

These are buyer-side or third-party records, not supplier marketing. Where a document is commercially sensitive we will ask the buyer for permission before sending it, and say so rather than sending a redacted page that proves nothing.

The part involved