How do you track and document the impact of engineering deviations on PPAP performance and feedback?

Engineering deviations are changes or modifications to the design, specifications, or materials of a product that are requested or approved by the customer or the supplier during the production process. They can be temporary or permanent, and they can affect the quality, functionality, or performance of the product. How do you track and document the impact of engineering deviations on PPAP performance and feedback? PPAP, or Production Part Approval Process, is a standardized method of verifying that a supplier can produce parts that meet the customer's requirements and expectations. It involves submitting samples, documents, and records to demonstrate the capability and conformity of the production process. In this article, we will discuss how to manage engineering deviations in PPAP and how to communicate their impact to the customer and the supplier.

1 Identify the deviation

The first step in dealing with engineering deviations is to identify them clearly and accurately. You need to know what the deviation is, why it occurred, who requested or approved it, when it was implemented, and how it affects the product or the process. You also need to determine if the deviation is temporary or permanent, and if it requires a new PPAP submission or not. Depending on the nature and scope of the deviation, you may need to perform additional tests, inspections, or measurements to verify its impact.

Add your perspective

Pratheush V - (PMP®)

PMI - PMP® Certified Project Management Professional | Ex. Caterpillar Inc | Ex. Nissan-Renault India | New Product Introduction | Engineering Change Management | Service Engineering | Logistics & Supply Chain
Report contribution
Having a good understanding of the engineering standards will really help identifying the deviations. Also a if you have a connected platform for all the team members can input comments and report the findings will also makes things easy. Also carefully reviewing the engineering spec and having a good knowledge on the part usage will do a great deal

Like

2 Document the deviation

The second step is to document the deviation and its impact in a formal and consistent way. You need to use the appropriate forms, reports, and records to capture the details and evidence of the deviation. For example, you may need to use an engineering change notice (ECN), a deviation request (DR), a deviation approval (DA), a dimensional report, a material certification, a test report, or a control plan. You also need to update the PPAP documentation package accordingly, and include any relevant attachments, references, or comments.

Add your perspective

Pratheush V - (PMP®)

PMI - PMP® Certified Project Management Professional | Ex. Caterpillar Inc | Ex. Nissan-Renault India | New Product Introduction | Engineering Change Management | Service Engineering | Logistics & Supply Chain
Report contribution
A systematic and organised documentation will make a large difference here. Keep a standardized template for reporting deviation will make the job easy. Visual evidence will make the job easy and categorizing the deviation based on severity will help to prioritize the action items.

Like

3 Communicate the deviation

The third step is to communicate the deviation and its impact to the customer and the supplier. You need to inform them of the deviation as soon as possible, and explain the reasons, the effects, and the actions taken. You also need to obtain their approval or feedback on the deviation, and address any concerns or questions they may have. You may need to use different methods of communication, such as emails, phone calls, meetings, or presentations, depending on the urgency and complexity of the deviation.

Add your perspective

4 Track the deviation

The fourth step is to track the deviation and its impact throughout the production process. You need to monitor the performance and quality of the product or the process with the deviation, and compare it with the original or expected standards. You also need to measure and record any variations, defects, or issues that may arise due to the deviation. You may need to use different tools and techniques, such as charts, graphs, tables, logs, or software, depending on the type and level of data you need to collect and analyze.

Add your perspective

5 Review the deviation

The fifth step is to review the deviation and its impact after the production process. You need to evaluate the results and outcomes of the deviation, and determine if it met the customer's requirements and expectations. You also need to identify any lessons learned, best practices, or improvements that can be applied to future PPAP projects. You may need to use different methods and sources, such as feedback surveys, audits, reviews, or reports, depending on the scope and purpose of the evaluation.

Add your perspective

6 Report the deviation

The sixth and final step is to report the deviation and its impact to the customer and the supplier. You need to summarize and present the findings and conclusions of the deviation, and highlight any achievements, challenges, or opportunities. You also need to provide any recommendations, suggestions, or actions for further improvement or follow-up. You may need to use different formats and media, such as documents, slides, videos, or webinars, depending on the audience and context of the report.

Add your perspective

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

Add your perspective

How do you track and document the impact of engineering deviations on PPAP performance and feedback?

1

2

3

4

5

6

7

1 Identify the deviation

2 Document the deviation

3 Communicate the deviation

4 Track the deviation

5 Review the deviation

6 Report the deviation

7 Here’s what else to consider

Production Part Approval Process (PPAP)

Rate this article

Thanks for your feedback

More articles on Production Part Approval Process (PPAP)

More relevant reading