Shown is a sample of a control plan at St. Paul Brass & Aluminum. “We don’t charge for the actual
paperwork of the PPAP—for the doing of it,” Hartigan said. “Our customers’ point is, they are asking us to prove we are making the parts correctly, and they don’t think they have to pay for that. I think that is pretty reasonable and it is our outlook, too.” However, St. Paul Brass & Aluminum will charge for additional services the PPAP may require, as with any other run of cast- ing, such as additional X-ray testing, nondestructive testing, test bars, etc. “Not every part is going to go
through the same PPAP scrutiny,” Hel- geson said. “Some are more critical than others, and to say they all have the same levels of risk would not be correct.” Suppliers with PPAP experience
have an advantage, but metalcasters new to the process can successfully present a PPAP, as well, with clear expectations and communication from the customer. St. Paul Brass & Aluminum’s first
PPAP came while the metalcaster happened to be creating standard worksheets for every job. “We had already done some flow analysis and had begun training our operators on critical points in the job,” Hartigan said. “Going through the first PPAP, we were able to use that to map out the steps in the process.”
With one PPAP done, additional documentation becomes easier. “Every part is different and there
will be some customization,” Hartigan said. “But, in terms of laying out how it is molded in our foundry, it will be the same. Once you have done it once, it is easier to go back in and say, ‘OK, this is how this part might be different.’” As Helgeson said, emphasis on
quality always grows, and metalcast- ers should preparing for more cus-
tomers, including smaller OEMs, to require PPAP and other quality control requirements. “Te more dynamic companies
have new designs and are really look- ing to the future,” Hartigan said. “I think it is good. It’s not just some- thing to say, ‘We have quality now.’ Reviewing the PPAP helps us make sure we are still doing the things we said we were doing a couple of years ago.”
Process flow diagrams are required in Section 2 of the PPAP. September 2013 MODERN CASTING | 45
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