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 production line from a German facility to a Romanian subsidiary to optimize costs while maintaining strict VDA quality standards.
- A Quality Documentation Specialist (or PPAP Coordinator) is responsible for creating and validating all elements of the PPAP package.
- Managing technical specifications for foam density and hardness while navigating the transition from the German “PPA” (VDA 2) system to the international “PPAP” format, which is required for site relocations. Key Documentation Deliverables. In the automotive industry, transferring the production of car foam seats from Germany to a plant in Romania (such as those in Western or Southern Romania where clusters of German suppliers often locate) requires a specialized Quality Engineer to manage the VDA 2 (PPA) or AIAG PPAP documentation. This process ensures the new Romanian site can meet the same quality, quantity, and timing requirements as the original German location.
Our Solution
With our expert on site, the following documents must be recreated or updated for the Romanian site to gain Part Submission Warrant (PSW) approval:
- Process Flow Diagram: Mapping the new production layout in Romania, from mold cleaning and chemical injection to the final “crushing” and trimming of seat pads.
- PFMEA (Process Failure Mode and Effects Analysis): Identifying potential risks in the new facility, such as incorrect chemical mixing or mold temperature deviations.
- Control Plan: Defining inspection points for physical and mechanical properties of the foam batches produced in the Romanian plant.
- Initial Process Study (Capability): Proving the new equipment in Romania can consistently achieve a Cpk ≥ 1.67 for critical foam dimensions.
- Measurement System Analysis (MSA): Ensuring Romanian lab equipment and operators can accurately measure foam hardness and density.
- Material Test Results: Verifying the PU foam formulation meets the car manufacturer’s specific chemical and durability requirements.
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.
- By strictly following VDA 2 (PPA) standards during the transfer, the Romanian site proves it can produce foam seats with the same hardness, density, and safety specifications as the original German facility.
- Cost Efficiency: The transfer successfully leverages Romania’s competitive labour costs and tax incentives while maintaining OEM-required quality levels.
