PPAP and First Article Inspection Documentation

KastMfg produces complete PPAP documentation packages (Levels 1-) and detailed first article inspection reports as standard deliverables on all new production programs. This page describes what each document contains, the format options available, and typical delivery timelines.

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First Article Inspection (FAI) Report -Standard on Every New Program

A First Article Inspection report is issued on every new or significantly changed production program before production approval is granted. KastMfg does not release a program to scheduled production without customer approval of the FAI.

FAI Report Contents

Section 1: Part Identification

• Part name, part number, drawing revision level, date
• KastMfg program number and production order reference
• Machine number and die set identification
• Production batch date and lot traceability

Section 2: Dimensional Results

• Every dimension on the customer drawing, measured on CMM with actual values
• Nominal, tolerance, actual measurement, and deviation for each dimension
• Color-coded pass/fail status per dimension
• Number of samples measured (standard: 5 pieces minimum; 30-piece for Cpk data)
• CMM equipment identification and calibration status

Section 3: Material Certificate

• OES spectrometer analysis results
• Alloy specification (ASTM B85, JIS H5302, ASTM B86, or customer specification)
• All elements measured vs specification limits
• Heat number and production date

Section 4: Process Parameters

• Key injection parameters at time of FAI sampling (fast shot velocity, peak pressure, die temperatures, cycle time)
• Confirmation that parameters are within control plan specification

Section 5: Special Test Results (where applicable)

• Pressure decay / nitrogen test results (per part serial number)
• Helium leak test results
• X-ray classification (ASTM E505)
• Tensile/hardness results from witness specimens
• T5/T6 heat treatment records

Section 6: Visual Inspection

• Surface condition report (cosmetic surface quality, flash status, ejector pin marks)
• Gate witness assessment
• Photographs of first article samples (standard: 3- photos covering all faces)

FAI Report Format

KastMfg issues FAI reports in:

• KastMfg standard format (English language, PDF)
• Customer-specific format (where customer provides the template)
• VDA 3.1 / AIAG first article format for automotive programs

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PPAP Documentation -Levels 1 Through 5

Level 1 -Warrant Only

Deliverable: Signed Part Submission Warrant (PSW) only.

KastMfg's PSW confirms: part number, drawing revision, material certification compliance, dimensional conformance, and production process compliance. Signed by KastMfg Quality Manager.

Delivery time: 3- business days after first article approval.

Level 2 -Warrant + Limited Supporting Data

Deliverable: PSW + dimensional results (first 5 pieces) + material certificate.

Delivery time: 5- business days after first article approval.

Level 3 -Warrant + Complete Supporting Data (Standard)

The full PPAP package. Delivery time: 10-15 business days after first article approval.

Level 3 package elements from KastMfg:

Element	KastMfg Deliverable	Format
Process flow diagram	Complete from ingot receipt to shipping	Flowchart PDF
PFMEA	Process-specific for casting + all secondary ops	AIAG PFMEA table
Control plan	All controls + inspection activities	AIAG control plan format
MSA (Gage R&R)	Studies on all gauges used for critical characteristics	AIAG MSA format, %GR&R <10%
Dimensional results	100-piece layout (all drawing dimensions)	CMM report, pass/fail marked
Material certificates	OES chemistry report per melt batch	EN 10204 2.2 (3.1 on request)
Performance test results	Pressure test records, X-ray (if applicable)	Test records per part
Initial capability study	Cpk on all Special Characteristics	SPC charts, Cpk values
Lab documentation	CMM + gauge calibration certificates	PDF
Sample parts	3- production parts from FAI run	Physical + labeled
PSW	Part Submission Warrant	AIAG format, signed

Level 4 and Level 5

Prepared per customer-specific requirements. KastMfg has experience with VDA (German automotive), AIAG (North American automotive), and customer-proprietary PPAP requirements.

Level 5 (on-site review) can be accommodated for customers requiring review at KastMfg's facility.

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Process Capability Data -Understanding What KastMfg Reports

For initial capability studies (PPAP element 12), KastMfg:

• Measures a minimum 30-piece sample from a production lot (not from dedicated "PPAP run" conditions)
• Calculates Ppk for initial capability (population-based, appropriate for new process) and Cpk for ongoing capability
• Targets Ppk >=1.67 on Special Characteristics before PSW submission
• Reports actual values -not "we expect to achieve" estimates

If initial capability falls below 1.33 on any characteristic, KastMfg holds the PSW, investigates root cause, implements corrective action, and re-samples before submitting.

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MSA / Gage R&R -Measurement System Verification

KastMfg performs Gage R&R studies on all measurement systems used for critical characteristics before PPAP submission:

• CMM programs: repeatability verified with 3-operator, 2-replicate study
• Pressure test equipment: linearity and bias study against reference leak rate
• Optical gauges (vision systems): repeatability study on production fixture

Standard acceptance: %GR&R < 10% (excellent); 10-20% (acceptable with consideration); >30% (action required).

Gage R&R reports issued in AIAG format with all raw data and statistical analysis.

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Timing -When to Request PPAP

PPAP is not a post-production document. It is a production qualification document that should be initiated at program launch, not requested after the first production order is shipped.

Recommended timing:

Milestone	Action
Program launch (PO received)	Confirm PPAP level required and format
Tooling design review	Confirm MSA plan -which gauges need Gage R&R
First article trial	CMM first article; pressure test; X-ray (if required)
First article approval	Begin PPAP documentation assembly
30-piece production run	Cpk data collection
PPAP submission	10-15 days after 30-piece run
PSW approval (customer)	Customer-controlled timeline

Requesting Level 3 PPAP after you have already received the first production shipment creates timeline problems for both parties. Plan it at program launch.

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PPAP and FAI documentation inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China