PCP (Production control plan)

A PCP (ISO/TS 16949) is created by the quality department of a manufacturing company and serves both the quality manager and the production as indication of:

• all test steps to be performed,
• the product features to be controlled,
• the tools/equipment to be used,
• the applicable test procedures,
• the specified minimal test values,
• the required test interval,
• the handling of misconducting test criteria and it includes
• other elements that are used e.g. for the detection and traceability.

A PCP occurs e.g. as a result of a process FMEA and contains at least all measures necessary to safeguard the significant and critical characteristics. Usually, it is requested by a principal as an evidence of a functioning production surveillance and therefore has an external monitoring function within the quality management activities.

A PCP meets and goes beyond the scope of a Control Plan according to QS 9000.
 

PPAP (Production Part Approval Process)

The PPAP according to ISO/TS 16949 or QS 9000 is an instrument to check and to sample parts from mass production equipment and moulds regarding their dimensional and functional features corresponding to the drawing specifications.
Hereby the supplier proves the correct interpretation and implementation of the principal's development requirements, the presence of a certified and effective quality management and the successful production of first prototype samples.
The specifications of a standard-compliant PPAP were developed by the AIAG group (Automotive Industry Action Group) as part of the APQP. Existing minimum requirements may therefore be found in the APQP. Every principal is free to impose additional requirements beyond this minimum. A PPAP consists of at least 18 documents, including:

• component drawings
• design FMEA and process FMEA
• process flow diagram (overview of all production steps including the sub-supplier parts)
• control plan (similar to PCP)
• certifications of measuring devices and laboratory equipment
• documentation of prototype samples including the results of tests already conducted

Process capability study

Long-term study to evaluate a production process on how reliable it can be kept within the tolerance limits. The determined process capability index yields information about the median position, variation and the expected non-conformance rate of the affected process.