IATF 16949 FMEA, Control Plan and PPAP Example Templates
This IATF 16949 example pack links a PFMEA, a control plan and a PPAP element summary for one machined part. Seeing the three documents agree with each other is the fastest way to learn what customers and auditors expect.
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IATF 16949 PFMEA, Control Plan and PPAP Example Pack
Pack header
Supplier: Northgate Machining Ltd Customer: Tier 1 brake systems customer Part: BK-4471-B rev C, Brake caliper piston bore sleeve PPAP level: Level 3
1. Process FMEA extract (AIAG-VDA format)
| Step | Failure mode | Effect | S | Cause | Prevention | O | Detection | D | AP |
|---|---|---|---|---|---|---|---|---|---|
| OP 30: CNC finish bore | Bore oversize | Seal leak, loss of braking pressure in assembly test or field | 9 | Tool wear or thermal drift not compensated | Tool life counter; automatic offset update; scheduled in-process probing | 4 | In-process probe on every part; air gauge check every 25 parts; SPC chart | 3 | High |
| OP 30: CNC finish bore | Bore undersize | Piston will not assemble; caught at assembly | 6 | Wrong offset after tool change | Tool change setup sheet; first piece approval | 3 | First piece plus probe | 3 | Medium |
| OP 40: Deburr | Burr left at cross hole | Debris in brake fluid circuit | 9 | Brush wear | Brush change interval | 4 | Visual 100% with boroscope sample | 5 | High |
2. Control plan extract
| Step | Characteristic | Spec | Method | Sample size and frequency | Control method | Reaction plan |
|---|---|---|---|---|---|---|
| OP 30: CNC finish bore | Bore diameter 25.000 +0.013 / 0 mm | Per drawing BK-4471-B rev C | In-process probe, air gauge | 100% probe; air gauge 1 in 25 | SPC chart, tool life counter | Stop machine, contain parts since last good check, adjust offset, 100% sort back to last good gauge check, notify quality |
| OP 40: Deburr | Cross hole burr free | No burr visible at 10x | Visual with boroscope | 5 parts per hour | Operator check sheet | Hold lot, re-deburr, re-inspect |
3. PPAP element summary
| Element | Evidence for this part | Status |
|---|---|---|
| Design records | Customer drawing BK-4471-B rev C, ballooned copy | Complete |
| Engineering change documents | ECN list since rev B | Complete |
| DFMEA | Customer-owned design; supplier has process responsibility only | Not applicable |
| Process flow diagram | Receiving to shipping, with OP 10 to OP 60 | Complete |
| PFMEA | Section 1 of this pack | Complete |
| Control plan | Section 2 of this pack | Complete |
| Measurement system analysis | Gauge R&R on bore gauge, target under 10% of tolerance | Complete |
| Dimensional results | Full layout on 5 sample parts, all ballooned characteristics | Complete |
| Initial process study | Cpk on key characteristic from 30 or more consecutive parts, target at or above 1.67 for new processes | Complete |
| Part submission warrant | Signed PSW | Pending signature |
Review and approval
Examples are illustrative for a machined part. Ratings must come from your own team using the customer-approved AIAG-VDA scales, and action priority comes from the AP table, not from multiplying S, O and D. Check your customer-specific requirements for PPAP level and capability targets. Do not submit example data as real records.
Connect quality records to your ERP
Optional: a conversation about linking PFMEA, control plan and PPAP records to your ERP data.
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How to use the pack
Change the part, process step, characteristic and failure mode. The same entries flow into the PFMEA row, the control plan row and the PPAP summary, which keeps the documents consistent. Add more process steps in your editor after export. The example covers one critical bore and one burr risk, but a real pack has a row for every step and every failure mode.
How the three documents connect
The PFMEA says what can go wrong and which controls you rely on. The control plan turns those controls into specific methods, sample sizes and reactions that operators follow. The PPAP shows the evidence that the process actually delivers the characteristic. A high action priority in the PFMEA should always appear as a defined control and a stronger reaction plan in the control plan.
- Every special or key characteristic in the PFMEA appears in the control plan
- Every control plan method has a validated measurement system
- Every PFMEA detection control is something that really runs on the floor
- Capability study results back up the occurrence rating
AIAG-VDA action priority, not just RPN
The current AIAG-VDA FMEA handbook replaces the old risk priority number with action priority: High, Medium or Low, set from severity, occurrence and detection through a lookup table. A severity 9 failure with moderate occurrence and detection can still be High. Do not rank actions only by multiplying S x O x D. The example shows a High row to demonstrate that a recommended action and a strong reaction plan are expected.
Common mistakes
Auditors and customers repeatedly find the same weaknesses.
- A PFMEA copied from another part with no link to this process
- Control plan methods that do not match what operators actually do
- Detection ratings that assume checks that are not performed
- Capability studies from too few parts or from non-consecutive parts
- Forgetting to update the PFMEA and control plan after a process change
Frequently Asked Questions
What is included in a PPAP submission?
A full PPAP has up to 18 elements, from design records and PFMEA to control plan, MSA, dimensional results, capability studies and the part submission warrant. The level you submit decides which are sent and which are kept on file. The customer specifies the level.
Is the example data real?
No. All part numbers, ratings and results are illustrative. Use them for structure and the logic linking the documents, then replace them with your own team's ratings and your own measured data.
Does IATF 16949 require AIAG-VDA FMEA?
IATF 16949 requires FMEA and control plans with customer-specific requirements applied. Many OEMs now expect the AIAG-VDA method. Confirm in your customer-specific requirements which format and rating scales apply to you.
Can I export this to Word or Excel?
Yes. Export to Word, PDF or Excel after filling the fields. The tables export as tables, so you can extend them with more process steps and keep working in your preferred editor.
If your PFMEA, control plan and quality records live in different systems, we can help connect them to your ERP so changes flow through, with the AI layer running on your own servers.
Related Tools
PFMEA Worksheet with RPN (Excel Export)
Fill a process FMEA row by row. RPN is calculated from S, O and D and the worst risk is summarised for you.
Quality & InspectionControl Plan Template (PDF/Word)
Fill the header fields and get a formatted control plan with process rows, methods and reaction plan.
Quality & InspectionPPAP 18 Elements Reference Table
Searchable table of the 18 PPAP elements, the evidence a customer expects for each, and the common reasons submissions get rejected.
Quality & InspectionPPAP Part Submission Warrant Template
A fill-in part submission warrant summary with part details, reason for submission, level and declaration, exported as PDF or Word.
Quality & InspectionAIAG-VDA FMEA Action Priority Reference
A quick lookup of the AIAG-VDA FMEA steps, action priority meaning and how it replaces RPN.
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