{"id":3678,"date":"2026-10-16T09:00:00","date_gmt":"2026-10-16T01:00:00","guid":{"rendered":"https:\/\/sayoon-dc.com\/?p=3678"},"modified":"2026-10-16T09:00:00","modified_gmt":"2026-10-16T01:00:00","slug":"dc%e3%82%b3%e3%83%b3%e3%82%bf%e3%82%af%e3%82%bf-ppap%e8%87%aa%e5%8b%95%e8%bb%8a%e7%94%a8%e3%83%97%e3%83%ad%e3%82%b8%e3%82%a7%e3%82%af%e3%83%88","status":"publish","type":"post","link":"https:\/\/sayoon-dc.com\/ja\/blog\/dc-contactor-ppap-automotive-projects\/","title":{"rendered":"\u81ea\u52d5\u8eca\u30d7\u30ed\u30b8\u30a7\u30af\u30c8\u5411\u3051\u306eDC\u30b3\u30f3\u30bf\u30af\u30bfPPAP\u8981\u4ef6"},"content":{"rendered":"

DC contactor PPAP requirements should be agreed with the automotive customer before samples or production documents are submitted. Define the exact contactor configuration, approved design record, production process, evidence package and approval authority. PPAP connects production capability to the customer\u2019s requirements; it does not independently establish a DC interruption rating or approve a contactor for every vehicle application. Ask which submission level, customer-specific requirements and change-notification rules apply. Keep engineering qualification, regulatory or certification evidence, and production-part approval distinct so a complete document folder is not mistaken for an unrestricted application release.<\/p>\n

Start with the customer\u2019s approval route<\/h2>\n

The automotive customer determines the applicable approval process and its project-specific conditions. Obtain the current requirements through the authorized customer contact instead of copying an internet checklist. Establish whether the customer uses AIAG PPAP, another production-part approval framework, or a tailored process. Record the document edition, required submission level, site and part scope, submission timing and the person who can accept the package. A supplier\u2019s previous approval for another customer is useful experience, but it does not approve your ordering code.<\/p>\n

Use the AIAG PPAP manual information<\/a> as the primary framework reference. The public overview describes the purpose; obtain the applicable manual and customer documents for detailed requirements. This guide organizes practical questions for a contactor purchase and does not reproduce the manual, prescribe universal sample quantities, or replace the customer\u2019s approval decision. Resolve uncertain applicability before purchasing teams treat a submission as accepted.<\/p>\n

Freeze the contactor configuration and application inputs<\/h2>\n

Define the complete part number, coil option, contact arrangement, terminal orientation, mounting details and any included suppression or electronic control. Link those details to a controlled drawing and revision. A family name or nominal current is insufficient when variants differ in coil behavior, auxiliary contacts or main-circuit construction. State which party controls the design and which supplier changes require customer review. Keep the ordering description consistent across purchase orders, drawings, samples and test reports.<\/p>\n

Separately define the intended DC duty, control supply, installation environment and relevant equipment conditions. These inputs allow engineering to identify the evidence needed for application qualification. Do not assume that a production approval package contains every necessary high-energy switching test. If a rating, material declaration or qualification report is missing, record that gap explicitly rather than hiding it within a generic PPAP completion statement.<\/p>\n

\"CZWH100A-T
CZWH100A-T, illustrated from the linked Sayoon product original. This unpowered construction reference does not establish electrical ratings, certification, inspection limits or application approval.<\/figcaption><\/figure>\n

Connect the process flow, risk review and control plan<\/h2>\n

Follow the proposed production route from receiving through assembly, inspection, testing and shipment. Identify the steps that can affect the contactor characteristics controlled by the drawing. Examples can include variant identification, terminal assembly, coil selection and final contact configuration. The actual supplier process determines what belongs in the review; photographs alone cannot establish its controls. Ask how outsourced operations and purchased components remain linked to the approved route.<\/p>\n

The process risk review should inform the control plan and reaction decisions. A control that exists only in a presentation is not evidence that production uses it. Compare the documents with the instructions and records at the relevant operation. If a characteristic requires special control, agree its designation and method with the customer. Do not invent a special-characteristic symbol or a universal severity ranking simply because the component is used in a battery system.<\/p>\n

Use a submission matrix to prevent disconnected evidence<\/h2>\n

The following qualitative matrix is a planning aid. It is not the official list of PPAP elements and does not establish which documents must be submitted rather than retained. Confirm applicability and submission requirements with the customer. Give each evidence item an owner, revision and unresolved-question field so reviewers can distinguish an accepted result from an incomplete request.<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n\n
Check<\/th>\nRequired evidence<\/th>\nDecision or record<\/th>\n<\/tr>\n<\/thead>\n
Design identity<\/td>\nApproved drawing, part number and revision<\/td>\nConfirm the samples and all reports describe the same configuration.<\/td>\n<\/tr>\n
Production route<\/td>\nProcess flow and approved manufacturing scope<\/td>\nCheck that outsourced steps and final inspection are included.<\/td>\n<\/tr>\n
Risk and control<\/td>\nApplicable process risk review and control plan<\/td>\nConnect identified risks to controls and reaction decisions.<\/td>\n<\/tr>\n
Measurements<\/td>\nDimensional results and measurement-system evidence<\/td>\nReview instrument suitability, method and result identity.<\/td>\n<\/tr>\n
Performance<\/td>\nApplicable material and functional test evidence<\/td>\nSeparate production routine checks from application qualification.<\/td>\n<\/tr>\n
Production representation<\/td>\nCustomer-agreed production sample and run records<\/td>\nShow where, how and with which approved process samples were made.<\/td>\n<\/tr>\n
Release status<\/td>\nCustomer decision and required submission record<\/td>\nRecord full, interim or rejected status using the customer\u2019s actual terminology.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Make dimensional evidence traceable to the drawing<\/h2>\n

Number the drawing characteristics in a controlled way and connect each result to the inspected unit, method and drawing revision. Record units and the applicable tolerance instead of providing an unlabeled measurement sheet. Include the practical mounting and terminal interfaces when the customer drawing requires them. Where a feature cannot be measured by the proposed method, resolve the method before reporting a result. A visually similar product is not a substitute for dimensional evidence.<\/p>\n

NIST\u2019s metrological traceability guidance<\/a> distinguishes a supported measurement result from a broad claim about equipment. Consider the method, calibration relationship and uncertainty relevant to the acceptance decision. A calibration sticker alone does not show that a fixture or instrument can resolve the required tolerance. Keep measurement-system acceptance under the applicable customer process and avoid claiming that NIST approves the contactor or the supplier.<\/p>\n

Keep performance evidence within its actual scope<\/h2>\n

List the functional requirements that the customer expects the evidence to cover. For a contactor, carrying duty, interruption duty, coil operation, insulation, mechanical behavior and environmental conditions may require different methods and reports. Their applicability depends on the approved design and project. Ask which reports are qualification evidence and which checks are performed routinely during production. A low-energy continuity result cannot demonstrate a high-energy DC breaking capability.<\/p>\n

Review the exact tested variant, setup, conditions, acceptance criteria and report revision. Explain any family extrapolation or similarity argument and obtain engineering acceptance where required. Do not relabel an unrelated certificate or test summary as a complete application approval. If a supplier can provide only partial evidence, keep the limitation visible and define the additional work before the release decision. This protects both purchasing and engineering from conflicting interpretations of the same file.<\/p>\n

\"CZWH100A-T
CZWH100A-T, illustrated from the linked Sayoon product original. This unpowered construction reference does not establish electrical ratings, certification, inspection limits or application approval.<\/figcaption><\/figure>\n

Show that submitted samples represent production<\/h2>\n

Agree how the samples must represent the intended production process, including the manufacturing site, tooling, equipment, materials and relevant process conditions. Identify any prototype method or temporary substitution. Samples made through a different route can support design learning while failing to represent the process proposed for normal supply. Preserve their identity so an attractive sample photograph is not treated as proof of production readiness.<\/p>\n

Follow the customer\u2019s requirements for quantities, run conditions, capability evidence and submission timing. This guide does not prescribe a universal run duration, sample count or capability limit. If production cannot yet meet the agreed conditions, disclose the difference and request an authorized disposition. Keep retained samples, associated records and the submitted units connected through identifiers. The production lot traceability guide<\/a> explains how to preserve those links after stock is split or shipped.<\/p>\n

Separate approval status from shipment permission<\/h2>\n

Record the customer\u2019s actual decision and its scope, including part number, revision, site and any restrictions. A package uploaded to a portal is not necessarily approved. An interim approval, where the customer permits it, may have quantity, time or corrective-action conditions. Purchasing and production need the same visible status so an unresolved document does not disappear when the order becomes urgent.<\/p>\n

Assign owners to open issues and specify what evidence will close them. Preserve the original submission, subsequent revisions and customer responses rather than overwriting the history with a single green status. If an engineering deviation or temporary shipment permission exists, link it to the approval record and review its boundary separately. Do not present a generic supplier statement as permission for series production.<\/p>\n

Control changes after the initial approval<\/h2>\n

Agree which product, process, site, tooling or source changes require notification and which require a new submission or customer disposition. Apply the customer\u2019s actual rules rather than assuming every change is identical. A contactor may look unchanged while its coil variant, contact material, terminal arrangement or approved production route changes. Ask how the supplier identifies the effective lot boundary and prevents mixed unapproved configurations from entering a shipment.<\/p>\n

Keep a revision trail linking the earlier approved construction to the proposed change and its evidence. Review effects on both production controls and application qualification. A new production approval decision does not automatically resolve every engineering question. The manufacturer audit checklist<\/a> helps test whether the document-control process reaches the production bench, while the sample validation guide<\/a> addresses the separate technical release.<\/p>\n

Ask Sayoon for a scoped evidence response<\/h2>\n

The illustrated CZWH100A-T SPDT DC Contactor<\/a> is a construction reference, not a claim of automotive qualification, PPAP capability or customer approval. Before selecting it for a vehicle project, provide the required configuration, duty and customer evidence expectations. Ask which documents and production records can be supplied for that exact order and identify any unavailable items.<\/p>\n

Use the DC contactor selection hub<\/a> to organize application inputs. Send the customer\u2019s approval requirements alongside the RFQ, with document owners, timing and unresolved engineering questions. Keep a clear distinction between a supplier\u2019s ability to answer an inquiry and a formally accepted production package. The useful outcome is an auditable release decision supported by matching evidence, rather than a folder whose filenames merely resemble a checklist.<\/p>\n

Educational video: understand the contact arrangement<\/h2>\n

The Electrician U explanation below introduces how a coil operates contactor contacts. Use it to understand the distinction between control and main circuits before reading an inspection drawing. It provides general education, rather than a test procedure or approval of the illustrated Sayoon model.<\/p>\n