Tick what is done on your new part launch and give each step an owner and a due date. The check shows which of the eight steps are ready, what is still open, what is overdue, and what was done out of order, like a capability run before the gages were proven. Print it as the launch plan.
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The eight steps
| Step | What has to be true |
|---|---|
| 1 Set up the launch | PPAP level known, special characteristics found, process flow drawn, PPAP plan owned and dated. |
| 2 Write the PFMEA | Every process step walked, risks rated, actions decided, with the people who run the process. |
| 3 Build the Control Plan | Every characteristic controlled, every row has a reaction plan, every high risk lands on a row. |
| 4 Train the station | Work instruction released at a revision, operators proven on a planted bad part. |
| 5 Prove the gage | Gage R&R on every gage for a key characteristic, failed gages fixed and rerun. |
| 6 Make the first article | Production parts, every characteristic numbered with a result, gage recorded. |
| 7 Run at rate | Production speed and tooling, capability measured on the whole run. |
| 8 Submit the PPAP | Required elements at the required level, records agree, warrant checked before signing. |
Worked example
A made up launch has steps 1 and 2 finished. In the Control Plan, the high risks do not all land on a row yet, and the plan was due three days ago. The station is not trained and no Gage R&R has been run, but a first article has already been measured and every characteristic is numbered on the drawing.
The check returns two of eight steps ready and one overdue, and points at the Control Plan as the next step. It lists the open item, the high risks with no row. It also flags the first article as done before the gages were proven, because a good result can come from a bad gage.
A step only counts as ready when the steps it depends on are ready too. Tick every box on the run at rate with no gage study behind it, and the run shows as on hold, not ready.
Why the order matters
Each record on a launch feeds the next one. The PFMEA feeds the Control Plan, the plan feeds the work instruction, and the gage study has to come before the capability run or you measure the gage, not the process. When the paperwork is filled in after the process is built, the PPAP records disagree and come back rejected. The path is laid out in new part launch.
This is a screening check of what you tell it. It cannot tell if a step was done well. Your customer sets the PPAP level, the run size and the capability minimum, so follow their requirements first.