Case Study 2

Case Study 2: Transferring the production of several foam products for the automotive industry from Germany to a plant in Romania, AIAG PPAP documentation management and submission to client.

The Challenge

  • The Project: Relocating a polyurethane (PU) foam laminating production line from a German facility to a Romanian subsidiary to optimize costs while maintaining strict VDA quality standards.
  • A PPAP/PPA specialist in this case, is responsible for creating and validating all elements of the PPAP package, ready for submission to customer.
  •  Completing this PPAP/PPA submission process in time demonstrate that the Romanian site can meet the same quality, quantity, and timing requirements as the original German location. 

Our Solution

With our expert on site, PPAP/PPA document packages were created or updated for over 50 products for the Romanian site to gain Part Submission Warrant (PSW) approval.

  • The work contracted focused on supporting domestic team in creating and preparing the documentation packages for all products subject to approval/reapproval. 
  • Coordination of PPAP/PPA documents package to ensure all customers requirements are met.

 

Outcome, Implementation and Success Factors

  • Successful achievement of PSW (Part Submission Warrant) approval for the new site, enabling a seamless transition of mass production without supply chain disruption.
  • Customer Approval: Documentation is typically submitted at Level 3 (PSW with full supporting data) to the OEM, and mass production cannot start until the customer signs off on the PSW. Customer Satisfaction: Successful PPAP outcomes lead to positive feedback from OEMs. 
  • Knowledge has successfully been shared between the German and Romanian teams and local staff got support from external consultant to understand complex VDA requirements.
  • Operational Readiness: The Romanian plant has reached full capacity by validating local equipment and operators through the PPAP process.
  • Cost Efficiency: The transfer successfully leverages Romania’s competitive labour costs and tax incentives while maintaining OEM-required quality levels.