JLR Customer Specific Requirements For Ppap: Scope

OPERATIONAL
JLR-STN-550990, ISSUE LEVEL 3.4

JLR CUSTOMER SPECIFIC REQUIREMENTS FOR PPAP
THE JAGUAR LAND ROVER WAY
OVERVIEW CONTENT AUTHOR CONTENT OWNER

Rob Gordon (rgordon9) Rob Gordon (rgordon9)
This standard defines Jaguar Land Rover Limited's (JLR)
Customer Specific Requirements for the Production Part LAST PUBLISHED NEXT REVIEW DATE
18/12/2019 44183.61
Approval Process (PPAP).
OWNING FUNCTION(S) OWNING LOCATION

STA United Kingdom
SCOPE
WHY
1.1 OBJECTIVE/PURPOSE
To define deviations, additions or clarifications on JLR's requirements for use of AIAG's PPAP version 4.0 as used by
production suppliers. The AIAG PPAP process shall be the core tool for completing PPAP in support of JLR's Design and
Approve the Manufacturing Process procedure.
1.2 RISKS
Failure to follow these requirements can jeopardise the quality of event of PPAP and the Design and Approve the
Manufacturing Process.
WHAT
2.1 SCOPE AND EXCLUSIONS
These CSR's apply only to the use of the PPAP process for production suppliers to JLR, referred to as "the organisation".
2.2 RETENTION OF RECORDS
The organisation shall ensure that all documents and records either specified by Jaguar Land Rover Limited or created by the
organisation in order to demonstrate compliance with PPAP, have copies filed in the PPAP file.
The PPAP file and contents may use any suitable media (hard copy or electronic etc.) but shall comply with the IATF16949
requirement “7.5.3 - Control of documented information”. Upon completion, the PPAP file shall be retained according to
IATF16949 requirement “7.5.3.2.1 - Record retention” and shall be retained for the life of the part plus 12 years.
WHO
3.1 CONSULTATION PARTICIPANTS
Russ Perry (rperry19)
3.2 APPROVERS
SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

RET ENT I O N JL R- RM P I T EM 25 . 0 1 S + 1 2
JL R- ST N- 55 0 9 9 0 UNCO NT ROL L ED WHEN DO WNLO ADED O R PRI NT ED PAG E 1 OF 1 0
JL R Cu st o me r Sp e c i f ic Re qu i re me n t s fo r PPAP
I SSUE 3 .4 , L AST REVI EWED 1 8 / 1 2/ 2 0 1 9
OPERATIONAL

Russ Perry (rperry19)
WHERE
4.1 APPLICABILITY
Applicability Operational
Functions/Departments STA
JLR Locations United Kingdom, Europe Region, China Region, North America
Region, Overseas Region
4.2 APPLICABLE KEY WORK SYSTEM(S)
6.08.01 Global Quality Strategy Development
4.3 APPLICABLE IT SYSTEM(S)

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NARRATIVE
1. Applicability (PPAP section “Introduction”)
The "authorised customer representative" is the Supplier Technical Assistance (STA) engineer assigned to the organisation
site. STA Engineers are identified in Jaguar Land Rover Limited SIM (Supplier Improvement Metrics) on the Jaguar Land Rover
Limited Supplier Portal for each organisation manufacturing site.
Note: In this document, in alignment with PPAP 4.0, unless otherwise noted, the term "organisation" refers to the manufacturing
sites of external suppliers manufacturing production parts and products for Jaguar Land Rover Limited.
2 .Submission of PPAP (PPAP section 1.1)
The organisation shall submit PPAP as stated in Jaguar Land Rover Limited's Phased PPAP Requirements Handbook,
available through the Jaguar Land Rover Limited Supplier Portal.
The organisation shall ensure that all documents and records either specified by Jaguar Land Rover Limited or created by the
organisation in order to demonstrate compliance with PPAP, have copies filed in the PPAP file.
The PPAP file and contents may use any suitable media (hard copy or electronic etc.) but shall comply with the IATF16949
requirement “7.5.3 - Control of documented information”. Upon completion, the PPAP file shall be retained according to
IATF16949 requirement “7.5.3.2.1 - Record retention” and shall be retained for the life of the part plus 12 years.
The organisation shall maintain version control over documents as defined by IATF16949. The records in the PPAP file shall be
the document version used at the time of PSW and shall clearly distinguish between this and subsequent versions up to the
latest live version where documents are subject to ongoing review and update.
3 .Design Record (PPAP section 2.2.1)
For a design record to be acceptable, the design must be released and authorised for production in the Jaguar Land Rover
Limited Worldwide Engineering Release System (WERS).
The organisation shall ensure that the release level of the product specified by Jaguar Land Rover Limited Product
Development Engineering matches the product release level specified in the Supply Confirmation Plan from Jaguar Land Rover
Limited.
3.1. Branding
Organisations shall comply with the E108 Jaguar Land Rover Limited Automotive Parts and Accessories Branding directive,
available through the Jaguar Land Rover Limited Supplier Portal and specified in the PLMJLR.00.0028 Branding and Coding
drafting standard, available through the Jaguar Land Rover Limited Supplier Portal.
4. Reporting of Part Material Composition (PPAP section 2.2.1.1)
Jaguar Land Rover Limited materials reporting requirement and compliance details are specified in Jaguar Land Rover
Limited’s Restricted Substance Materials Standard (RSMS) STJLR.99.9999.

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Materials reporting must be done via an IMDS (International Material Data System) submission.
The current Jaguar Land Rover Limited RSMS package is released each year in the "News" section of IMDS.
5. Marking of Polymeric Parts (PPAP section 2.2.1.2)
Design record requirements for marking of polymeric parts are specified in the drafting standard PLMJLR.00.0029, which is
cascaded as part of the Environmental Statement of Work.
6. Customer Engineering Approval (PPAP section 2.2.3)
The organisation shall obtain documented Jaguar Land Rover Limited Product Development Engineering approval of DV
(Design Verification) and PV (Production Validation) tests of the initial sample parts. The organisation shall conduct the PV
testing on parts/products which were produced at "run at rate" (refer to the Jaguar Land Rover Limited Phased PPAP
Requirements Handbook for a definition of "run-at-rate").
7. Failure Mode and Effects Analysis (PPAP sections 2.2.4 and 2.2.6)
Organisations shall meet the requirements of the Jaguar Land Rover Limited FMEA handbook when developing DFMEAs, and
PFMEAs (available through Jaguar Land Rover Limited Supplier Portal).
7.1. Design FMEA
Authorisation to create a single DFMEA for a family of similar parts or materials used in similar applications, environments, etc.
is available from Jaguar Land Rover Limited Product Development Engineering. Design FMEA(s) for safety and regulatory
component(s) prepared by design responsible organisations require Jaguar Land Rover Limited Product Development
Engineering approval.
All design Special Characteristics shall be recorded on the Special Characteristics Summary Sheet (SCSS) and a copy must be
retained in the PPAP file.
Jaguar Land Rover Limited reserves the right to review all organisation-developed DFMEAs.
7.2. Process FMEA
Characteristic traceability is required from the DFMEA through the PFMEA to the Control Plan. Such traceability can be
documented on the "Special Characteristic Summary Sheet" available through the Jaguar Land Rover Limited Supplier Portal.
Jaguar Land Rover Limited reserves the right to review all organisation-developed PFMEAs.
8. Control Plan (PPAP section 2.7)
For all PPAP submission levels (1 through 5), Control plan(s) for safety and regulatory (inverted delta) component(s) require
Jaguar Land Rover Limited Product Development Engineering review.
The Control Plan shall include provisions for on-going monitoring of process capability, stability and control.
Jaguar Land Rover Limited reserves the right to review all organisation-developed Control Plans.

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8.1. Extraordinary Control Plans.
An Extraordinary Control Plan is an appendix to the Pre-Production Control Plan and defines non-standard processes and
controls implemented in support of Interim PSW’s. It shall utilise the same document format as the Pre-Production Control Plan.
These must be used for all deviations to the Pre-Production Control Plan where a non-standard process and/or process
controls are being used.
It must define what the non-standard process(es) are and what the means of control is to ensure the product fully conforms to
the Design Record or agreed deviation as defined on a WERS Alert.
The supplier must formally incorporate this document into their record system for traceability purposes and include it in the
PPAP file.
The document reference number, issue level and date for the Extraordinary Control Plan shall be defined on the PPAP
Checklist as part of the request for a WERS Alert. This metadata will be recorded in the WERS Alert itself to ensure traceability.
When the non-standard processes and/or process controls are removed and the production process fully complies with PPAP
requirements, the Extraordinary Control Plan shall be withdrawn and the Pre-Production or Production Control Plan followed.
The Extraordinary Control Plan shall identify a withdrawn date and be retained by the supplier in their record system for the life
of the PPAP file.
9. Measurement Systems Analysis Studies (PPAP 2.2.8)
Where measurement analysis studies are performed using software, the software is to be validated using standard input data
sets and checked using corresponding expected output results.
The preferred method for calculating Gauge R&R is by using the ANOVA method, since the ANOVA method allows
identification of the operator contribution, whereas the Average and Range or Range methods do not. Refer to the AIAG
published SPC manual, and the ANOVA method is available through commercial statistical software packages and the AIAG
APQP forms disk available from AIAG.
The organisation shall report the number of distinct categories (ndc). All variable gauge R&R studies should have a minimum
of 5 distinct categories (See Measurement Systems Analysis Reference Manual published by AIAG, refer to "ndc" in the index).
Gauge R&R as a percent of study < 10% is acceptable (the parts used for the Gauge R&R study must be representative of a
production run). If Gauge R&R as a percent of study is greater than 10%, but less than 30%, contact STA to determine if the
Gauge R&R is acceptable. If Gauge R&R > 30%, it is unacceptable and the organisation shall implement a corrective action
plan to improve measurement capability.
10. Material Test Results (PPAP section 2.2.10.1)
Where Jaguar Land Rover Limited specifies that materials are to be purchased from an approved supplier, the organisation
should contact the buyer to determine appropriate materials suppliers.
11. Initial process studies - Actions to be taken when acceptance criteria are not satisfied (PPAP 2.2.11.6)
The modified control method shall include techniques to incorporate mistake proofing methods into the manufacturing process
to prevent the shipment of non compliant product to Jaguar Land Rover Limited facilities.

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Note: examples of mistake proofing methods include the modification of manufacturing processes to detect and discard non
compliant product (e.g., poke-yoke), or a gauge to ensure product compliance to specification where the process does not meet
the capability requirements. This is not the addition of a temporary manual inspection process at the end of the line.
The organisation shall continue to determine sources of variation, improve the process with permanent corrective actions, and
improve the process to meet the capability requirements.
11.1. The following are examples of measurement equipment mistake proofing methods
2.1 For Variable Gauges:
Two sided tolerances:Tolerances used for 100% inspection gauges can be reduced by the extent of the gauge R&R as a
percent of tolerance of the gauge(s) being used in the 100% inspection methodology. The typical practice is to remove half the
gauge R&R as a percent of tolerance from the upper specification limit and the other half from the lower specification limit.
Example: A variable gauge is used to check a product characteristic of 600 microns +/- 40 microns (this equates to 80 microns
specification tolerance spread). Additionally, this variable gauge has a gauge R&R as a percentage of tolerance of 20%. The
upper limit compensated for gauge capability would be 632 microns (600+40- 80 x 0.2/2) (Upper Specification – (Specification
tolerance spread x (% tolerance Gauge R&R)/2) and the lower limit compensated for gauge capability would be 568 microns
(600-40 + 80 x 0.2/2) (Lower Specification + (Specification tolerance spread x (% tolerance Gauge R&R)/2). This example
assumes the gauge error is equally distributed. Continue process variation reduction efforts until a Ppk greater than 1.67 is
achieved, or until STA approval is received.
One-sided tolerances: For a "less than" tolerance specification (e.g. length less than 20 mm) subtract three gauge R&R
standard deviations from the tolerance specification. For a greater than tolerance specification (e.g. plating thickness greater
than 10 microns) add three gauge R&R standard deviations to the tolerance specification. The converse applies if it is a "less
than" tolerance.
"Greater than" example: A variable gauge is used to check the length of a product characteristic. The product specification is
greater than 150 microns. The gauge R&R standard deviation is 2 microns. The specification compensated for gauge error
would be greater than 156 microns (150 + 3 x 2)
"Less than" example: A variable gauge is used to check the length of product characteristic. The product specification is less
than 150 microns. The gauge R&R standard deviation is 2 microns. The specification compensated for gauge error would be
less than 144 microns (150 - 3x2)
If business reasons exist to deviate from the recommendations listed above, contact STA to obtain concurrence.
Continue process variation reduction efforts until an acceptable process capability is achieved, or until STA approval is
received.
12. Qualified Laboratory Documentation (PPAP 2.2.12)
As per IATF16949 requirements.
13. Appearance Item Approvals (AAR) (PPAP 2.2.13)

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All parts/products having appearance criteria shall be reviewed and approved by the appropriate Jaguar Land Rover Limited
activity. For the current AAR process contact your Customer Authorised representative.
After approval signatures have been obtained from the designated Jaguar Land Rover Limited representative, the AAR form
shall be included with the Warrant.
Note 1: Appearance items are: all interior, exterior, luggage compartment, and select under bonnet components which are
visible to the customer. Appearance approval includes, but is not limited to: overall appearance, surface quality, colour, texture,
and gloss.
Note 2: Visual "match-to-master" is the specified requirement for AAR sign-off. Numeric evaluations should only be used for on-
going quality control after visually acceptable parts/products are attained.
Note 3: There shall be no customer discernible texture, colour or gloss mismatch between mating or adjacent parts where the
design theme has designated they should appear harmonious.
14. Part Submission Warrant (PPAP sections 2.18 and 5)
See the Jaguar Land Rover Limited Phased PPAP Requirements Handbook available through the Jaguar Land Rover Limited
Supplier Portal for PPAP level and PSW submission requirements.
Warrants for Priority components (during vehicle launch) shall be reviewed and approved by both STA and PD as appropriate.
For post Job#1 PPAP submissions, the organisation is not to ship production quantities to the Jaguar Land Rover Limited
facilities until after PPAP and functional trial approval or functional trial waiver are obtained. The functional trial approval or
functional trial waiver is obtained after PPAP approval, and is managed by Plant Vehicle Team (PVT).
Note: For a supplier resource, or other reason for submission as deemed appropriate by the customer authorised
representative, a line trial should be carried out prior to submission of the Warrant. This additional Line Trial prior to Warranting
does not negate the need to carry out a functional trial approval once the part is warranted.
For PPAP submissions during a vehicle launch, the launch builds constitute the "functional trials" and therefore provide
approval to ship parts subject to plant releases.
Organisations are permitted to submit multiple part numbers (same family of parts) on a single PSW with all part specifics (e.g.,
prefix, base, and suffix) clearly noted on the PSW or on an attachment to the PSW.
The organisation must allow for STA approval timing (at least one week) ahead of the sample promise date.
15. Change Notification (PPAP section 3)
Tier 1 and Jaguar Land Rover Limited Directed Tier 2 (or lower tier) suppliers to Jaguar Land Rover Limited are required to
obtain Jaguar Land Rover Limited approval prior to implementation of any organisation-initiated or supplier-initiated change per
the Jaguar Land Rover Limited SREA (Supplier Request for Engineering Approval) Process. The requirements of section 3.1 in
PPAP are met by following the SREA process (the SREA requirements are available through the Jaguar Land Rover Limited
Supplier Portal).
16. Records Retention (PPAP section 6)

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The PPAP file and PSW records shall be retained for the life of the active part plus 12 calendar years.
17. Appendix A – Completion of the Part Submission Warrant (PPAP sections 2.18 and 3)
See Jaguar Land Rover Limited's Phased PPAP Handbook for instructions on PPAP and PSW submission requirements,
available through Jaguar Land Rover Limited Supplier Portal.
18. Appendix G – Tyres – Specific Requirements
Organisations supplying tyres to Jaguar Land Rover Limited shall meet all requirements of PPAP.
The tyre appendix is not applicable to organisations supplying tyres to Jaguar Land Rover Limited.
19. Special Characteristics (PPAP Glossary)
Jaguar Land Rover Limited special characteristics are defined in the Jaguar Land Rover Limited FMEA handbook.
20. Labelling Requirement
For all shipments of new or changed product the organisation is required to follow local current practice – contact the local
Jaguar Land Rover Limited MP&L (Material Planning and Logistics) for assistance.
Note: Critical Characteristics are those product requirements (e.g., dimensions, performance tests) which are part
characteristics or process characteristics that can affect compliance with government regulations or safe vehicle/product
function, and which require specific organisation, assembly, shipping, or monitoring and are included on Control Plans. Critical
Characteristics are identified either by the inverted delta symbol (▼) or CC designation.
REVISION HISTORY
Date of Written / Revised by Issue Summary of and reason for the new issue / revision.
Issue/Revision level
1st Sep 2010 R.Gordon 1.0 Initial release of JLR document.
1st Mar 2016 R.Gordon 2.0 Section 8.1 updated to describe the requirement for and use
of Extraordinary Control Plans for non-standard processes.
9th Jun 2017 R.Gordon 3.0 Sections 2 and 16 updated to reflect JLR’s revised record
retention requirements for the PPAP file.
References to ISO/TS16949 updated to IATF16949.
12th July 2019 R.Gordon 3.1 Annual file review, no process changes.
9th Dec 2019 R.Gordon 3.2 Transferred contents to JLR Way template format, no process

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changes.
18th Dec 2019 R.Gordon 3.4 Correction of issue level number.

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APPENDICES
Appendix 1: Other Translations
 English (Master)
Appendix 2: Variations
There are no other variations available for this document.
Appendix 3: Waivers
There are no waivers for this document.
Appendix 4: Internal Controls
No internal controls apply to this document.

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OPERATIONAL

JLR-STN-550990, ISSUE LEVEL 3.4

OVERVIEW CONTENT AUTHOR CONTENT OWNER

OWNING FUNCTION(S) OWNING LOCATION

2.2 RETENTION OF RECORDS

Russ Perry (rperry19)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

Russ Perry (rperry19)

4.2 APPLICABLE KEY WORK SYSTEM(S)

6.08.01 Global Quality Strategy Development

4.3 APPLICABLE IT SYSTEM(S)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

1. Applicability (PPAP section “Introduction”)

2 .Submission of PPAP (PPAP section 1.1)

3 .Design Record (PPAP section 2.2.1)

4. Reporting of Part Material Composition (PPAP section 2.2.1.1)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

5. Marking of Polymeric Parts (PPAP section 2.2.1.2)

6. Customer Engineering Approval (PPAP section 2.2.3)

8. Control Plan (PPAP section 2.7)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

8.1. Extraordinary Control Plans.

9. Measurement Systems Analysis Studies (PPAP 2.2.8)

10. Material Test Results (PPAP section 2.2.10.1)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

11.1. The following are examples of measurement equipment mistake proofing methods

2.1 For Variable Gauges:

12. Qualified Laboratory Documentation (PPAP 2.2.12)

As per IATF16949 requirements.

13. Appearance Item Approvals (AAR) (PPAP 2.2.13)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

14. Part Submission Warrant (PPAP sections 2.18 and 5)

15. Change Notification (PPAP section 3)

16. Records Retention (PPAP section 6)

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

17. Appendix A – Completion of the Part Submission Warrant (PPAP sections 2.18 and 3)

18. Appendix G – Tyres – Specific Requirements

19. Special Characteristics (PPAP Glossary)

1st Sep 2010 R.Gordon 1.0 Initial release of JLR document.

References to ISO/TS16949 updated to IATF16949.

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

18th Dec 2019 R.Gordon 3.4 Correction of issue level number.

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

JLR-STN-550990, ISSUE LEVEL 3.4

Appendix 1: Other Translations

There are no other variations available for this document.

There are no waivers for this document.

Appendix 4: Internal Controls

No internal controls apply to this document.

SECURI T Y CL ASSI F I CATI O N Pro p ri e t a ry

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