Global Supply Management

PPAP Process Checklist \ Sign Off Sheet instructions

In addition to these requirements you must meet all Nexteer Supplier Requirements. Nexteer Automotive has moved to electronic PPAP documentation submission and storage. This is especially essential when multiple sites may need the same in ormation. See the Nexteer Supplier Bulletin for electronic submission details, titled, Electronic Submission of PPAP. The irst page o the pac!age should be the approved PPAP chec!list rom the Nexteer Advanced "uality #ngineer $A"#% or Supplier "uality #ngineer $S"#%. The Nexteer A"#&S"# must re er to the electronic version o this chec!list or speci ic requirement notes and comments by section $See Nexteer Automotive 'orm '()*) + PPAP ,hec!listlocated in the Nexteer Supplier .eb Site%. ,onsult your A"#&S"# or more in ormation. These instructions have been revised to con orm to the latest update o the PPAP Process ,hec!listand are speci ic to Nexteer Automotive. These revisions are intended to correspond to AIA/ PPAP 0 th #dition manual- including Nexteer Supplier Requirements. The latest version o the PPAP 1anual2 www.aiag.org NOTE 2 Nexteer3s 4#1 ,ustomer requirements may supersede the PPAP ,hec!list requirements. In this instance- the 4#1 ,ustomer requirements will be discussed during the Tech Review. ! a! "esign #ecor$ % "ra&ing + Send in a legible copy o the Print with the submission. #ach and every eature $including Print Notes- Standard Tolerance Notes and Speci ications% must be 5ballooned6 or 5road mapped6 to correspond with the inspection results. Notes on the print must also be included on the ballooned print- and on the inspection data. The print must be at a minimum7 a Nexteer chec!ed and signed print. b! "esign #ecor$ ' (unctional ) Material ) Test Specifications + Send in a legible copy o all customer design records and speci ications. NOTE* 'or Speci ications that are copyright protected- Supplier is to provide Nexteer with a document stating the revision level o speci ication used. +! Engineering Change "ocuments + Any mar!ed and signed drawings- speci ications etc.authori8ing a Supplier to deviate rom the design record. 'or Nexteer- a deviation must normally be authori8ed by way o an #ngineering Permit. Applicable #ngineering Permit$s% should be included in this section o PPAP. I the Supplier PPAP submission includes changes re erenced on a submitted Supplier ,hange Request $S,R% orm- then copies o the approved S,R must be included in this section o PPAP ,! Customer Engineering Appro-al + This is a section which is included in latest AIA/ PPAP manual- but which has little to no application or Nexteer Automotive components. Nexteer3s engineering department will not typically provide an approval regarding PPAP prior to the submission itsel . As such- this section will typically be le t blan!. This section may be used in the case o 4#1 engineering approval- i required or a 9irected :uy component. .! "esign (MEA /"(MEA!0 if Supplier is "esign #esponsible ; The 9esign '1#A is required i the Supplier is responsible or the design o the part $'or example2 :lac! :ox design%. 4therwise- the 9esign '1#A is the responsibility o Nexteer Automotive. I the Supplier eels that the 9esign '1#A is proprietary- they should insert a sheet in the PPAP pac!age stating their position. The latest version o the '1#A 1anual2 www.aiag.org

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2! Process (lo& "iagram /P("! + The Process 'low 9iagram must ollow the process rom receipt o raw material and receiving inspection- through any warehousing and shipping steps. It should also include any ?9oc! Audits? and 'inal Inspections. The P'9 shall comprehend all potential paths that a part can ta!e in the process- including inspection- containment- rewor!- and scrap. The P'9 must include material shipped to sub;contractors and the returning o the material bac! to the Supplier3s plant. The Nexteer ormat available on the Nexteer Supplier .eb Site $Appendix (><*% is the pre erred P'9 ormat. 3mportant2 There must be a one;to;one match o the 4peration numbers between the P'9'1#A and ,ontrol Plans- to allow or easy cross;re erencing o the documents $unless or 5 amily6 o parts%. @P,3s and ",I3s must be noted on P'93s. 4! Process (MEA /P(MEA! + The P'1#A is a living document and should2 :e initiated be ore or at the easibility stage:e initiated prior to tooling or productionTa!e into account all manu acturing operations rom individual components to assembliesandInclude all processes within the plant that can impact the manu acturing and assembly operations- such as shipping- receiving- transporting o material- storage- conveyors or labeling.

The P'1#A needs to be reviewed by Nexteer prior to the PPAP submission. #nsure that the P'1#A meets AIA/3s requirements or Severity- 9etection and 4ccurrence ratings. @P,3s and ",I3s should be ran!ed with a Severity number o Aor higher on all P'1#A3s. 3mportant* The Supplier P'1#A should be reviewed with the Nexteer P# to ensure that the P'1#A severity ran!ings are equal to or higher than the Nexteer 9'1#A ran!ings. There must be a one;to;one match o the 4peration numbers between P'9- '1#A and the ,ontrol Plan to allow or cross; re erencing o the documents. The latest version o the '1#A 1anual2 www.aiag.org

5! 5a! Pre%6aunch Control Plan /inclu$ing EPC plan! + 1a!e sure that the Pre;Baunch ,ontrol Plan is clearly mar!ed as such and is signed. The Pre;Baunch ,ontrol Plan must meet all o the requirements o the Production ,ontrol Plan with the ollowing additions2 C#arly Production ,ontainment3 must be documented in the Pre;Baunch ,ontrol Plan- as a separate step. #P, is above and beyond what is done in the rest o the Pre;Baunch ,ontrol Plan. #P, must be per ormed as a step segregated rom the production process- Dust prior to pac!aging&shipping. .hen easible- all Special ,haracteristics are to be ())E inspected during #P,. The Pre;launch ,ontrol Plan must document increased sample si8es and&or sample requencies or quality chec!s per ormed during the pre;launch period. $#ach Process 4peration in the Pre;Baunch ,ontrol Plan must have a higher sample si8e and&or sample requency than what is noted in the Production ,ontrol Plan%. The Pre;Baunch ,ontrol Plan must ollow the process rom receipt o raw material through shipping steps. 3mportant2 There must be a one;to;one match o the 4peration numbers between P'9- '1#A and the ,ontrol Plan to allow or cross;re erencing o the documents. 5b! Pro$uction Control Plan + 1a!e sure that the Production ,ontrol Plan is clearly mar!ed as such and is signed. It must ollow the manu acturing process rom receipt o raw material through shipping steps7 including Receiving Inspection- 9oc! Audits and 'inal Inspections. ,ontrol methods or both product and process characteristics should be listed. A procedure

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number is not acceptable in the control method column unless a brie description o the procedure or a copy o the procedure is included. I wor! instructions are re erred to in the ,ontrol Plan- they should be included in the PPAP pac!age. The ,ontrol Plan must include the print revision number and letter and be comprehensive $i.e. it must include all part dimensional characteristics and notes provided on the blueprint. These characteristics must be listed on the ,ontrol Plan with the process characteristics that lin! to them in a cause and e ect relationship%. The ,ontrol Plan must be part- or part amily- speci ic. Sub;Supplier ,ontrol Plans should be available or Nexteer review $i requested%. Anything required to ma!e a de ect; ree part needs to be addressed in the ,ontrol Plan. Sample si8es must be de ined in number o parts. Sample requencies must be de ined as a speci ic quantity o parts- or as a speci ic time interval. /eneral terms such as2 5Per :ox6- 5#ach Bot6- #ach Production Run6- 5#ach load6- etc- are not acceptable. 3mportant* There must be a one;to;one match o the 4peration numbers between P'9- '1#A and the ,ontrol Plan to allow or cross;re erencing o the documents. 7! Measurement System Analysis /Gage #8#! ' All gages in the Control Plan must ha-e a Gage #8# stu$y complete$9 'or the PPAP Submission7 only /age RFR3s or Special ,haracteristics are to be submitted. :ariable Gage #8#;s + 1ust be done and included in the PPAP submission even i the gage is a hand tool- such as micrometers or calipers. This also includes ,11. Gariable gage studies are to be o the ormat2 > operators- > trials- using () parts. The () parts need to be representative o the process. All variable gage RFR studies should have a minimum o = distinct categories. The pre erred method or calculating the gage RFR is by using the AN4GA method. /ages not meeting the acceptance criteria per the AIA/ 1SA manual shall have a containment plan $such as ())E inspection- gage improvement- or other means%. /age study records shall be maintained. The preferred tool for reporting this data is Minitab Attribute Gage #8# + At a minimum a @appa Study must be completed with a =)x>x> method. The A"#&S"# can provide an electronic template or this attribute study- which will streamline the gage study method and eliminate con usion and inconsistencies with Nexteer3s expectations. 3mportant2 I a ,11 is used to complete the initial process capability study on a eature that is chec!ed with an attribute gage in the ,ontrol Plan- then a variable gage study must be completed on the ,11 and an attribute study on the attribute gage. The latest version o the 1SA 1anual2 www.aiag.org <! "imensional #esults + 9imensional result must correspond to the 5Road 1apped6 or 5:allooned6 Print & 9esign Record 9etails $including any and all drawing notes%. #ach data point must indicate 5In Spec&4ut o Spec6- and&or 5Pass&'ail6. An Interim Recovery .or!sheet must be illed out by the Supplier- or any requirements not met- and signed by the Nexteer A"#&S"# and Product #ngineer. A total o = pieces per Galue Stream are to be chec!ed or 9imensional Results. .hen reporting on the dimensional results o a True Position- and&or Pro ile- /9FT requirement- also report the dimensional results or the :asic 9imensions that are associated with the /9FT requirement. A"#&S"# is to request that the Supplier identi y any bonus tolerance resulting rom 11, or B1,. =! =a! Material Certifications ' Include any material certi ications & material test results relating to the part and the base materials rom the Supplier3s internal lab or outside contracted lab. Identi ication o the Speci ication and Bot o material must be identi ied on the ,ontrol Plan. I there are material speci ications noted on the print- you must provide data that shows

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con ormance to those speci ications in the PPAP pac!age7 spea! to your Nexteer A"#&S"# or details. =b! Test #esults /Performance0 "urability! ' Include any per ormance or durability tests as prescribed in the design record7 including drawings and unctional and validation speci ications. The required level o detail $i.e. summaries vs. charts vs. raw data% shall be as directed by Nexteer Product #ngineering and&or Nexteer A"#&S"#. ! 3nitial Process Capability Stu$ies /Cp>)Pp>! + I the Nexteer Product #ngineer or A"#&S"# has not identi ied @P,3s or special characteristics $",I3s% to measure- the Supplier should select not less than one dimension to demonstrate process capability. (*= piece capability studies are required at time o PPAP or all @P,3s and ",I3s and other characteristics directed by Nexteer. The (*= piece data points should come rom the >)) piece PPAP production run- in time; ordered subgroups o > to = pieces. The sampling plan is to be documented and pre;approved by Nexteer. Hnless otherwise directed by the Nexteer A"#&S"#- each cavity o a multiple cavity mold- or multiple tool process- must have its own capability study 4n the initial process studies or special characteristics $i.e.- ",I3s- @P,3s- etc% the Supplier needs to demonstrate that the process is stable and in control through the use o a control chart. Normality and capability must also be demonstrated. The pre erred statistical so tware pac!age is 1initab and the above can be shown using the 5,apability Six Pac!- within 1initab.6 The acceptance criteria or the process indices is per the AIA/ PPAP requirements. +! ?ualifie$ 6aboratory "ocumentation ' I testing is per ormed in a SupplierIs internal lab- they must provide a copy o their quality certi ication. The Supplier should also provide documentation o the appropriate laboratory scope. I an external lab is used- send a copy o outside lab certi ication and the scope o accreditation $must be IS4 (A)*=&A*BA certi ied or regional equivalent%. As a best practice- the Supplier should indicate speci ically which labs were used or the applicable part number $i.e. by test log or other indication o laboratory usage%. Baboratories which were not used expressly or indirectly in the testing o the applicable part number should not be re erenced. ,! Appearance Appro-al #eport + Any part that is color matched- needs graining- or other appearance approval must have an appearance approval report attached to the PPAP. ,onsult the 4#1 ,ustomer Speci ic Requirements or speci ic use o orms.

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.! Sample Pro$uct to Plant ' Send the sample product to the using plant as instructed by the PPAP purchase order or by the Nexteer A"#&S"# 9 The Supplier will provide the shipping in ormation $i.e. the carrier name- and shipment trac!ing number% to the Nexteer A"#&S"#- and to the person receiving the PPAP at the Nexteer Plant. As a best practice- this shipping in ormation may be included in this section in the PPAP submission. Samples need to be properly identi ied with the Nexteer /lobal Sample and PPAP Babel $'orm J>0K>%. The Babel must be illed in and printed on bright orange paper by the supplier- and irmly a ixed to All 'our Sides o the container or box. Paper dimension must be A0- K;(&*6x((6- or similar si8e. The label template may be obtained rom the Nexteer Supplier .eb Site. It can be ound by navigating to Nexteer.com and selecting Suppliers in the top right ribbon. 'rom there- select Processes rom the le t banner- then Shipping and Babeling. ,lic! on the /lobal Sample and PPAP Babel. 4nce open- select your pre erred language rom the bottom tabs.

2! Master Sample ' Per AIA/ PPAP 1anual 0th edition2 5The organi8ation shall retain a master sample or the same period as the production part approval records- or $A% until a new master sample is produced or the same customer part number or customer approval- or $:% where a master sample is required by the design record- ,ontrol Plan or inspection criteria- as a re erence or standard. The master sample shall be identi ied as such- and shall show the customer approval date on the sample. The organi8ation shall retain a master sample or each position o a multiple cavity die- mold- tool or pattern- or production process unless otherwise speci ied by the customer.6 Note that PPAP 0th edition includes some guidelines which detail conditions upon which this requirement can be waived. The waiving o this requirement shall ultimately be determined by the Nexteer A"#&S"#- and can be indicated on the chec!sheet $as 5N46 to being required%. NOTE 2 The Nexteer A"#&S"# will direct the Supplier on the number o 1aster Samples to be retained. 4! Checking (i@tures ) Ai$s ) Gages + I needed to veri y- the Supplier will provide a list- or drawing- and&or duplicate ixture & aids & gages to the Nexteer Plant with the PPAP parts. 5! Ne@teer Supplier #eAuirements ' These are PPAP submission requirements that are speci ic to Nexteer Supplier components. .hile several o these items are typically mandated- at least under certain conditions- the inal applicability o any o these requirements pertaining to a certain component PPAP submission shall be indicated on the PPAP Process ,hec!list by the Nexteer A"#&S"#. $3mportant2 The latest revision o the Nexteer Supplier Requirements should be requested rom the A"#&S"# by the Supplier and then re erenced as the ormal requirement documentation. Points below are identi ied as help ul lessons learned rom past PPAP experiences.% 5a! 3nterim #eco-ery Borksheet /( =.+! + I or any reason the Supplier anticipates less than ull approval $ or example2 print changes being made by engineering but not yet released- etc.% a Nexteer Interim Recovery .or!sheet must be illed out and included in the pac!age. The Interim wor!sheet needs to include the Nexteer Product #ngineerand Nexteer A"#&S"#- signatures prior to the PPAP submission to the Nexteer 1anu acturing Plant. The A"#&S"# is responsible to obtain the signatures. SoC Confirmation 6etter ; A copy o the Substance o ,oncern ,on irmation Approval must be included in the PPAP pac!age. Suppliers must submit into I19S. I any materials prohibited by the /A9SB Bist are contained in the product- the Prohibited Substance Reporting 'orm $*>))))))% approved by the ,hie ,hemist $or So, Team%

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must be included in the pac!age and the appropriate box be noted on the Part Submission .arrant. NOTE* I19S Recipient or Nexteer Automotive is L A=K)(. Any other recipient code submitted will be reDected. The speci ic in ormation or suppliers on how to ill out an I19S request or Nexteer- as well as the prohibited substance reporting orm- can be ound on the Nexteer Supplier .eb Site. See Also + Nexteer Supplier Requirements- Section (.0 or urther in ormation. 5c! Supplier Characteristic Summary /SCS! (orm ' This is a summary o technology and quality strategy or the critical and notable product eatures and process controls o the component. It must include a summary o certain process and capability in ormation concerning all @P,3s- ",I3s- and other characteristics as directed on the orm. This electronic orm is to be initiated by the Supplier or initial program review- updated throughout process development phase- and ultimately submitted with the PPAP pac!age. Instructions are included in the comments or each column heading within the electronic orm. Ne& Tool 3nformation* Photos0 "escription 8 "ra&ing + 'or new tools and ixtures or which any payment is expected to be made by Nexteer- some minimal in ormation shall be required to be included in this section o the PPAP submission in order to help substantiate Supplier claims o tooling expense. This in ormation should include + at a minimum + recent photo$s%- drawings- and brie written description. In ormation should describe applicability o this tool regarding any other usage by the Supplier beyond the express purpose o creating or ensuring quality o the submitted component. Supplier Packaging 3nformation /SP3! (orm ' Include the approved SPI orm $minimum requirement + sign;o should be completed at the preliminary stage o the SPI 'orm%. 'or urther in ormation regarding this orm- Supplier should consult with the Nexteer :uyer. Applicability o this section to a particular PPAP submission shall be prescribed on the chec!list by the A"#&S"#. Contact 6ist ' I requested by the A"#&S"# per the chec!list- the Supplier shall include a list o !ey Supplier contacts in the PPAP submission. This will increase the visibility o !ey contacts which may be required or Nexteer business purposes. (actory (loor 6ayout ' As requested by the A"#&S"# per the chec!list. Nexteer Problem Solver Access Confirmation Nexteer Problem Solver access is MANDATORY for all production component Suppliers to Nexteer. The Nexteer AQE/SQE will indicate YES as a requirement for PPAP submission if there is any doubt concerning the Suppliers access and/or usage capability for Nexteer Problem Solver. In this case, the Supplier must include in the PPAP submission, evidence of having registered and accessed the Problem Solver application. (Example: Screenshot from Nexteer Problem Solver). I the Nexteer A"#&S"# has con idence o the Supplier3s access and usage o the Nexteer Problem Solver application- then he&she may indicate 5N46 + not required + on the chec!list. Assessments + Nexteer A"#&S"# should indicate whether special surveyswor!sheets- or questionnaires are to be submitted with PPAP. These assessments shall pertain to the location o applicable processes- whether at Supplier or sub;tier Supplier. 'or example- i the Tier;( Supplier purchases the heat treat process rom their Tier;* Supplier- then the heat treat system at the Tier;* Supplier shall be assessed using the

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,"I;N wor!sheet- and shall be included in the Tier;( PPAP to the customer. These assessments can include2 ,"I;N $Oeat Treat System Assessment% ,"I;(( $Plating System Assessment% ,"I;(* $,oating System Assessment% ,"I;(= $.elding System Assessment% ,"I;(A $Soldering System Assessment% 'ord .;OTJ supplement $In which case- the word 5other6 would be circled and a note could be added at bottom o PPAP chec!list to indicate the assessment type% Toyota .eld Survey $In which case the word 5other6 would be circled and a note could be added at bottom o PPAP chec!list to indicate the assessment type%

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Other Customer Specific #eAuirements ; In addition to the requirements noted abovethe Supplier must meet all Nexteer Supplier Requirements noted in the Nexteer Supplier .eb Site- and&or :est Practices as noted by your Nexteer A"#&S"#. Some examples o these include2 Babels2 Include an example o the :arcode Babel that will identi y the parts prepared or shipping to Nexteer. 4rder the PPAP Pac!age in an electronic submission ormat- as required in the Nexteer Supplier Requirements. Re erence the Nexteer #lectronic PPAP Submission Instructions that is located in the Nexteer Supplier .eb Site. I applicable- include approved PPAP warrants- or all sub;tier Supplier components that have a Nexteer part number noted on the print.

7! Part Submission Barrant $re er to the latest AIA/ PPAP manual or the template% + A Part Submission .arrant 1HST be properly illed out. Any in ormation that is not illed out must have an explanation. #lectronic signatures are acceptable.

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