Understanding Authorised Engineering Change Documents in PPAP

In the context of the Production Part Approval Process (PPAP), Authorised Engineering Change Documents (AEC) are critical. These documents form one of the 18 essential elements required in a PPAP submission and ensure that any changes to the design or manufacturing process are properly managed and approved.

What are Authorised Engineering Change Documents?

Authorised Engineering Change Documents capture any approved modifications made to a product’s design, materials, or processes after initial approval. These changes could be driven by improvements, regulatory updates, cost optimization, or resolving production issues. The AEC document formally records the nature of the change, the reasons behind it, and its anticipated impact on the product or process.

Key Components of Authorised Engineering Change Documents

  • Design Changes: Modifications in the part's design, including changes in dimensions, materials, or functionality.
  • Material Changes: Switching or altering the materials used in the manufacturing process or components.
  • Process Changes: Adjustments in manufacturing methods, tooling, or equipment used to produce the part.
  • Location Changes: Moving production to a different facility, which may impact production consistency and quality.
  • Supplier Changes: Replacing a supplier for a component or material used in the production process.

Importance of Authorised Engineering Change Documents in PPAP

  • Ensures Traceability: AEC documents provide a record of all changes, ensuring that any alterations are traceable for future reference in case of issues or failures.
  • Customer Approval: Engineering changes must be approved by the customer before implementation, ensuring alignment and preventing unauthorized modifications.
  • Maintains Quality Consistency: Documenting and approving changes ensures that product quality is not compromised and that all changes are carefully evaluated.
  • Compliance with Industry Standards: Many industry standards, such as IATF 16949, require that engineering changes are thoroughly documented and authorized.
  • Risk Mitigation: Authorising engineering changes allows for risk assessments to be conducted, minimizing potential negative impacts on production or product quality.

Best Practices for Managing Authorised Engineering Change Documents

  • Thorough Documentation: Ensure that all aspects of the change, including reasons, impacts, and tests conducted, are fully documented.
  • Timely Customer Approval: Engage with customers early in the process to obtain timely approval and avoid production delays.
  • Clear Communication: Maintain open communication with all stakeholders involved, including suppliers and internal teams, to ensure smooth transitions when implementing changes.
  • Regular Reviews: Periodically review the engineering change process to ensure it remains effective and aligned with industry standards and customer expectations.
  • Version Control: Implement version control to manage updates and ensure the most current document is used in production.

Conclusion

Authorised Engineering Change Documents are a crucial element of the PPAP process, ensuring that any modifications to a product’s design or production process are properly evaluated, approved, and documented. This not only maintains product quality but also supports compliance with industry standards and reduces risks in manufacturing. By managing these documents effectively, companies can ensure smoother production transitions and sustained customer satisfaction.