COOPER-STANDARD AUTOMOTIVE

NVH CONTROL SYSTEMS DIVISION

PRODUCTION PART APPROVAL PROCESS CHECKLIST

THIS FORM MUST BE COMPLETED AND SUBMITTED AS PART OF YOUR PPAP SAMPLE
SUBMISSION PACKAGE. THAT PACKAGE MUST ALSO INCLUDE:

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1) ___ ___ Production Part Submission Warrant (AIAG Form CFG-1001)

2) ___ ___ Six (6) sample parts must be included with the sample
submission. The entire package must be shipped to the Using
Plant (For new jobs, the using plant should be defined in
Launch Meeting Notes). Please be sure to mark the package to
the attention of the responsible Sample Part Approval Activity,
as follows:
Dave McNall - Auburn Greg Layton – Mitchell
Victor Gonzalez – Coopermex Tommy Welch – El Dorado
The box must be wrapped with Yellow Sample Tape, as
provided by Cooper-Standard.

3) ___ ___ One Thousand (1000) Engineering Samples (unless otherwise

requested) must be shipped to the Using Plant (For new jobs,
the using plant should be defined in Launch Meeting Notes).
These samples need to be clearly marked with the Yellow
Sample Tape provided by Cooper. NOTE: The Engineering
Samples are due on the same day as the PPAP sample
submission package.

4) ___ ___ Any authorized engineering change documents (signed

Deviation Requests or Engineering Change Requests) not yet
incorporated into the design record but incorporated into the
part.

5) ___ ___ A full dimensional layout of the six (6) sample parts from item
#2 above, on an official PPAP Dimensional Results form, such
as AIAG Form CFG-1003. You must report the high and low
values for each dimension shown on the Cooper-Standard
Insert Drawing. Please be sure to list these dimensions in the
order that they appear on the Cooper-Standard Insert Drawing
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(dimensions should be marked numerically inside triangles). If
the dimensions are not marked numerically on the insert
drawing, please number them in an orderly fashion. Include a
copy of the Insert Drawing. In addition to the dimensions, all
notes or comments appearing on the Cooper-Standard Insert
Drawing are to be addressed on the inspection sheet. All
dimensions are to be reported in the units of measure used on
the Cooper-Standard Insert Drawing.

6) ___ ___ Form, fit, and function gages must be submitted, in pairs, along
with dimensional certification (in Metric) for all critical form, fit
and function dimensions. Construction dimensions need not be
reported. The gage drawing is also to accompany the gage
submission, along with the completed gage approval checklist.
An Auto Cad file, if available should also be included.

7) ___ ___ A completed Insert Tooling Information Form.

8) ___ ___ Material Certifications must be included for any purchased raw
material, including, but not limited to, aluminum, steel and
plastics. A mill certification supplied from the manufacturer will
normally be acceptable, provided it identifies material
composition by elemental chemistry and demonstrates
conformance to the appropriate customer specification. If the
manufacturer's certification is not satisfactory, independent
verification from an accredited laboratory is required. A copy of
the Scope of Accreditation for the laboratory must accompany
their data . The Scope must comply with ISO Guide 25 or GM
GP10 requirements. Any purchased components, such as bolts
and nuts, require material certifications as well. Please
remember that these documents will be closely scrutinized for
conformance. Any documentation which does not fully comply
with every aspect of the specification called out on the Cooper-
Standard Insert Drawing will be considered incomplete. This
may result in the formal rejection of your sample submission.
If any material specified on the insert drawing has a corresponding
Material Safety Data Sheet (MSDS), please supply a copy of it with the
sample submission.
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9) ___ ___ Material Safety Data Sheets (MSDS) are to be provided for any
process lubricants, chemicals, or coatings which may or will
appear on incoming components.

10) ___ ___ Documentation, including the raw data, for any Performance
Testing specified on the Cooper-Standard Insert Drawing must
be supplied. This data must be supplied for six (6) parts unless
otherwise noted in Launch Meeting Notes. Please be sure to
report all test data in the same units noted in the specification
or on the Cooper-Standard Insert Drawing. All testing must be
performed by an accredited/certified laboratory. A copy of the
Scope of Accreditation for the laboratory must accompany their
data. The Scope must comply with ISO Guide 25 or GM GP10
requirements.

11) ___ ___ Documentation for any Engineering Specification, such as a

coating or plating specification, must include whatever raw data
is necessary to demonstrate conformance to the ES in its
entirety. This data must be supplied for every ES noted on the
Cooper-Standard insert drawing and must be reported in the
same units noted in the specification. All testing must be
performed by an accredited/certified laboratory. A copy of the
Scope of Accreditation for the laboratory must accompany their
data. The Scope must comply with ISO Guide 25 or GM GP10
requirements. Please be certain that every section of the ES
has been addressed. Partial documentation or documented
nonconformance may result in the formal rejection of your
sample submission.

12) ___ ___ A Process Flow Diagram. Make certain that the entire process,
from receiving raw material to shipment of product is covered.

13) ___ ___ A Process Failure Mode and Effects Analysis (PFMEA). This
document should tie directly into the various steps in the
Process Flow Diagram. Please refer to the AIAG Potential
Failure Mode and Effects Analysis Manual.
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14) ___ ___ A Process Control Plan. This document should tie directly into
the various steps in the Process Flow Diagram, and should
mirror the PFMEA. All product and process related Significant
or Key characteristics are to be included, at a minimum. Do
not forget machine controls that are monitored.

15) ___ ___ For every Significant Characteristic or equivalent defined on the
Cooper-Standard Insert Drawing, a one hundred (100) piece
capability study is to be performed. The hundred pieces must
be composed of 20 subgroups of 5 samples each selected at
random from the thousand piece validation run. You must
include the Raw Data from the hundred samples used to
generate the study. Data submissions must include Xbar- & r-
charts. The data must show a Ppk of 1.67 minimum for a new
job, or a Cpk of 1.33 minimum for an existing job. Any study
showing results below those stated above must be
accompanied by a Corrective Action Plan which shows root
cause and spells out specific actions to be followed to improve
the process/product to acceptable levels.

16) ___ ___ Any significant characteristic or equivalent which will be treated
as an attribute characteristic will require a ‘one time only’
capability study showing variable data for one hundred (100)
pieces. The hundred pieces must be composed of 20
subgroups of 5 samples each selected at random from the
thousand piece validation run. You must include the raw data
from the hundred samples used to generate the study. Data
submissions must include Xbar- & r-charts. The data must
show a Ppk of 1.67 minimum. Any study showing a Ppk less
than 1.67 must be accompanied by a Corrective Action Plan
which shows root cause and spells out specific actions to be
followed to improve the process/product to acceptable levels.
In addition, certification that the entire thousand piece sample
run successfully passed through the certified attribute gage
designed to control the characteristic in question must be
provided. NOTE: For a significant characteristic designated as
an attribute measurement in the control plan, the supplier must
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establish a specific reaction plan for the containment and
disposition of nonconforming product between samplings.
Otherwise, the supplier is required to perform 100% inspection.

17) ___ ___ Measurement System Analyses (Gage R&R) for all equipment
used for the statistical studies called out in control plan, or for
new/modified gages or test equipment.

18) ___ ___ An early production containment plan (i.e. a pre-launch control
plan) as noted in the Launch Meeting Minutes, Appendix A.

19) ___ ___ A completed copy of the Packaging Information Form.

20) ___ ___ A completed copy of the Health, Safety, and Environmental Impact
Report for purchased components.

ANY DEVIATION FROM THIS STANDARD MUST BE REQUESTED IN WRITING PRIOR

TO SAMPLE SUBMISSION OR YOUR SAMPLE SUBMISSION WILL BE SUBJECT TO
REJECTION. APPROVAL OF ANY DEVIATION REQUEST WILL BE AT THE DISCRETION
OF COOPER-STANDARD AUTOMOTIVE, NVH CONTROL SYSTEMS DIVISION.
Prepared by : Don Muckenfuss Revision Date: 3-23-00
Document Number:06-08-00-04 Revision Level: 4900-5