Production Part Approval Process (PPAP) is core tool in manufacturing quality. This is the documentation methodology helps supplier to manage part development and meet customer requirements. In these documents one of the document is Record of Material Test Results.
In this article we will see everything you should know about material records in PPAP documentation.
Let’s dive in…
What is Record of Material in PPAP?
Record of material is documented evidence you submit to customer by mentioning all material details and their test results. It is like you tell your customer that we are using “e.g. Material” for manufacturing your part, which is compliance to all your specified chemical, physical and metallurgical requirement mentioned in design record or control plan.
Once you use such material as per customer requirement then your final product will meet all performance, functional, durability and safety requirements.
This record is very important in automotive, aerospace, and electronics industries, where material integrity directly impacts product quality and reliability.
Why Is the Record of Material Important?
- Compliance with Design Specifications
Material record confirm that material used in your part meet all design specifications as per design record (Drawing, customer design specification sheet). It will leads to avoid any future deviations, performance and part failure. - Quality Assurance
It helps to standardize the process of verification of material quality in regular production. - Traceability
Documented material test results helps manufacturers to track the material supplier for any defect or failure using material TC and batch code. - Customer Confidence
Providing ok material test results increase customer confidence in suppliers to deliver quality products.
Record of Material Test Result document
When you document material test results for PPAP, consider below details and formats,
1. Part Name, Part Number
Mention part details as per latest release customer drawing. Helos to have a traceability and identification.
2. Design Record change level
Add the design record with latest change level where all material details are written.
3. Authorized Engineering Change Documents
You can write Engineering change number of the change which is not yet added in latest drawings.
4. Supplier Details
Write material supplier name. If the material supplier is approved and suggested by customer, then mention supplier source along with vendor code and required details.
5. Laboratory Name
Add the name of laboratory where you have done all material tests.
6. Material Specification
Add material code or number, date and change level of material specification for which you are going to test the part material.
7. Type of Test and Testing Information
The information includes Date of testing, Quantity of material tested and Actual test, like tensile strength, hardness, or chemical composition.
8. Supplier Test Results
Mention actual results or the observation from the test. Also analyze the results and mention the result as accepted or rejected with remarks.
Record of material test result can be documented in any format as per customer requirement and your organizational requirement. But the condition is you should include all details as above so that it is clear and accurate.
You will get example format in AIAG PPAP manual also. But here I have provided the best format, you can download and use it without any issue.
How to do record of material documentation
Refer below steps to create your material result record,
- Identify Material Requirements
By considering drawing record and Control Plan, understand the chemical, physical, or metallurgical properties that we have to do testing for. - Conduct Material Tests
Conduct all required tests, for example tensile strength, hardness, and chemical composition measurement. Do these all test at an approved and standard lab facility. - Compile Results
Record test results, also mention all details, such as testing date and supplier information. - Review and Validate
Cross-check all results to make sure they meet customer requirements before submit to customer as a PPAP documentation. - Submit Documentation
The document should be signed by authorized personal if required. Add this document in Record of Material section of your PPAP submission package
Common Challenges while maintaining and preparing material records
Challenge 1: Non-Compliant Materials
Received material is not from trusted and approved supplier. Which is non-compliant and not fit to specification.
Solution: Make sure you source materials from customer-approved supplier only and validate material properties during initial development phases.
Challenge 2: Missing Data
Solution: Have a checklist to with all required details (e.g., test date, supplier name) are and fill it properly. This helps to capture all details and you will not miss it.
Challenge 3: Testing Delays
Solution: Make a strong relation and timely payment to accredited labs that can provide timely test results to avoid delays in PPAP submission.
Performance Test Results in PPAP
Performance test results are same as record of material in format point of view. But one point you need to understand is, performance test results describe the actual functional tests on material and their results.
It confirms that the part functions as per customer intended function and those results captured in Performance test result.
Refer below format for documentation of Performance test results as a part of PPAP submission.
Conclusion
The Record of Material Test Results is one of the PPAP document. It is the proof of materials meet design requirements.
For more information and other PPAP resources and quality tools, explore other articles on our website.
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