Quality Documents, PPAP & FAI Deliverables

We provide comprehensive quality documentation across all project stages—from prototyping and FAI to pilot runs and mass production. Our deliverables include detailed FAI reports, CMM inspection records, Material Certificates, and CoC. PPAP support scope is precisely tailored based on part criticality, CTQ requirements, and your specific customer quality plan.

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What Quality Documents Can We Provide?

Standard Inspection and Quality Records

Dimensional Inspection Report
Balloon Drawing
First Article Inspection Report (FAI)
In-process Inspection Records
Final Inspection Record
Visual Inspection Checklist

Material and Compliance Documents

Material Certificate (Mill Test Report)
Certificate of Conformity (CoC)
Resin Batch Traceability Record
RoHS / REACH Declaration (Upon Request)

Advanced Validation Documents

CMM Full Inspection Report
Gauge R&R Summary
Capability Study / Cpk Summary
Process Validation Record
Mold Trial Report (T1-T2 Report)
PPAP Level 1-3 Submission Support

Which Documents Are Available at Each Project Stage?

Prototype Stage

PHASE 01

Basic dimensional inspection report
Material confirmation (MTR)
Critical key feature check
Visual inspection summary

First Article / Sampling

PHASE 02

Full ballooned engineering drawing
Detailed FAI report
CMM report for critical dimensions
Mold trial / Setup validation report
Deviation list (if applicable)

Pilot Run / Pre-Production

PHASE 03

Updated project inspection plan
Process capability (Cpk) for CTQ
Gauge correlation & repeatability (GR&R)
Packaging verification record

Production Stage

PHASE 04

Final batch inspection records
Full batch traceability data
Raw material lot documentation
Certificate of Conformity (CoC)
PPAP package support (on request)

Super Ingenuity Quality Documentation Matrix by Project Stage including FAI CMM and PPAP

What Is Included in Our FAI Deliverables?

FAI Scope & Engineering Review

Approved 2D Drawing Sync
Revision Level Validation
CTQ Feature Identification
Actual Measured Data Log
Sampling Plan Alignment
Tolerances Stack-up Review

Typical FAI Package Contents

Ballooned Drawing (PDF)
Full Dimensional Report
Inspection Method Ref
CMM Report for CTQs
Visual Inspection Photos
Material Certs (on request)

When FAI Is Recommended

First Production Run
New Tooling Kick-off
Engineering Changes (ECN)
Supplier Transfer Programs
Tight Tolerance Verification
Critical Geometry Launch

Super Ingenuity FAI Deliverables Review and CMM Inspection for Precision Machined and Molded Parts

What PPAP Support Can We Provide?

PPAP Support Scope

Dimensional results
Material certifications
Process flow records
Inspection planning support
Sample submission
Capability data (CTQ)

Available Records

PSW Support
Dimensional results
Material certs
Initial process capability
Appearance approval
Control plan coordination

Common Industry Use

Automotive components
Industrial equipment
Medical device sampling
Regulated consumer goods
Electronic assembly
Energy & infrastructure

Super Ingenuity PPAP documentation support and FAI inspection capability using CMM equipment

Note: Engineering and documentation support is available based on agreed scope, specific drawing requirements, and project phase. Please consult with our quality team to define the exact submission levels required for your program.

What Inspection Methods Do We Use to Generate the Records?

Dimensional Verification

High-precision Calipers
External/Internal Micrometers
Digital Height Gauges
Precision Pin Gauges
Thread & Plug Gauges

Coordinate Measurement

CMM for critical dimensions
Geometric Profile Analysis
Positional Tolerance Check
GD&T Data Extraction
3D Scan vs. CAD Comparison

Process & Capability

Critical-to-Quality (CTQ) Review
Formal Sampling Plans (AQL)
Repeat Measurement Controls
Cpk/Ppk Capability Studies
Statistical Process Control (SPC)

Injection Molding Specific

Comprehensive Mold Trial Eval
Cavity-to-Cavity Consistency
Shrinkage Analysis vs. Drawing
Cosmetic & Gate Area Review
Parting Line & Flash Inspection

Super Ingenuity Metrology Verification and CMM Inspection for Quality Documentation

Which Documents Are Common for Injection Molding vs CNC Parts?

Document Type	Injection Molding	CNC Machining
Process Validation	T1/T2 Trial Reports	Setup Validation Records
Core Dimension	FAI (Cavity-to-Cavity)	CMM Inspection Report
Material Assurance	Material Cert & Traceability	Material Cert & CoC
Batch Consistency	Process Window Confirmation	Tool Wear Control Log

Injection Molding Quality Documentation including T1 T2 Trial Report and Cavity Comparison

Injection Molding Projects

Raw Material Certification
T1/T2 Mold Trial Reports
First Article Inspection (FAI)
Appearance Approval Reference
Cavity Comparison Analysis
Process Window Confirmation

CNC Machining Quality Deliverables CMM Inspection Report and Setup Validation

CNC Machining Projects

FAI Dimensional Records
Detailed CMM Inspection Report
Machining Setup Validation
Tool Wear Control Records
Material Compliance Certs
Certificate of Conformity (CoC)

What We Need from You to Prepare the Right Documentation

Before Quotation or Sampling

2D Drawing with Revision Level
3D CAD File (STEP/Parasolid)
CTQ or Key Dimensions Identified
Detailed Material Specifications
Cosmetic & Finishing Requirements
Estimated Annual Volume (EAU)
Industry Compliance Standards

If PPAP or Custom Records Required

Requested Submission Level (1-3)
Customer Specific Templates
Special Characteristics Definition
Packaging & Labeling Specs
Traceability & Lot Requirements
Specific Metrology Instructions

Super Ingenuity documentation preparation requirements including 2D drawing revision and 3D CAD file review

When to Request FAI, PPAP, or Additional Quality Documentation

New Tooling Launch

Critical for validating mold or die precision before releasing mass production orders. Ensures steel dimensions match CAD requirements.

New Supplier Onboarding

Essential for the first batch to establish a quality baseline and verify that our process capability aligns with your SQE standards.

Transfer Tooling Program

Required when moving existing molds. We re-validate process stability and part consistency in our manufacturing environment.

Tight Tolerance Features

Provides objective evidence for critical-to-quality (CTQ) dimensions where microns determine final assembly performance.

Regulated Industry Parts

Mandatory compliance for Automotive (IATF 16949), Medical (ISO 13485), or high-reliability Aerospace components.

MP Approval Gate

Final verification step before moving from Pilot Run to Mass Production, ensuring all quality gates have been officially cleared.