Powerful, Easy-to-Use, Lightning-Fast
APQP and PPAP Management Software.
Simplify the creation and management of internal (customer requested) and supplier PPAPs. Automate PFMEA and Control Plan creation. Cut PPAP creation, review and approval time from days to hours. Speed-up the new product introduction process.
SIMPLIFY PPAP CREATION AND MANAGEMENT. SPEED UP NEW PRODUCT INTRODUCTION.
SPEED UP PPAP CREATION
“Before 1factory, one PPAP would take me at least a week from start to finish.
Now, with 1factory, it takes me an hour, maybe two, from start to finish. I'm at 168 PPAPs for the year already (with a 1-person team)".
there are also fewer mistakes in them. One of our customers forwards our PPAPs along to their customer, and they can't believe how fast they get accepted. Read the Case Study
Christy Wiggam, Quality Manager, J&L Manufacturing
OVERVIEW: PPAP MANAGEMENT
WHAT IS THE PRODUCTION PART APPROVAL PROCESS (PPAP)?
The Production Part Approval Process (PPAP) is a critical new-product introduction (NPI) process that validates a manufacturer's capability to consistently produce high-quality parts at the rate required by the customer.
This comprehensive evaluation examines everything from engineering documentation and raw materials to special processing steps and functional testing.
The PPAP process enables suppliers to evaluate manufacturability, identify design improvements, and establish robust production processes.
The PPAP process enables buyers to validate all steps of the supplier's manufacturing process, and verify capacity.
Only after successful PPAP completion is a part considered ready for volume production.
WHAT MAKES PPAP CHALLENGING?
Today's manufacturers face increasingly complex PPAP requirements while managing both customer (internal) and supplier submissions.
Teams struggle to coordinate comprehensive documentation reviews spanning engineering drawings, process flows, control plans, and test results.
The challenge doubles when managing both internal PPAPs for customers and incoming PPAPs from suppliers, each requiring detailed documentation and different approval workflows.
Without efficient systems, teams waste countless hours manually creating PFMEAs and Control Plans, tracking submissions, and chasing approvals - turning this crucial new product introduction step into a major bottleneck that delays production launches by weeks or months.
THE 1FACTORY PPAP SOLUTION
1factory transforms PPAP management by automating the entire process for both internal and supplier submissions.
1factory's' Process Library accelerates PPAP creation by automatically generating PFMEAs and Control Plans.
Quality teams can create, review, and approve PPAPs in hours instead of days, while maintaining consistency and revision control.
1factory provides real-time visibility into supplier PPAP submission status and automates the validation of submissions vs requirements.
The result is a dramatic reduction in PPAP creation and approval time, transforming a traditional bottleneck into a competitive advantage for suppliers, and speeding up the NPI process for buyers.
PPAP & APQP FEATURES
1 Internal (Customer) PPAPs
Author, collect and manage the various PPAP elements - Process Flow, Control Plan, PFMEA, Measurement Data, Certs, Gage R&R etc. - from various departments (engineering, manufacturing, quality control etc.) into a PPAP package for delivery to a customer.
2 Supplier PPAPs
Assign PPAPs to suppliers with a clear list of requirements and due dates. Define levels and required documents by level. Receive PPAPs from suppliers within 1factory. Provide real-time feedback with powerful Messaging capability. Review and approve individual requirements and notify suppliers of status change.
3 PPAP Levels
Easily define and manage custom PPAP levels by product type and/or customer. Define custom lists of required and optional documents by PPAP level.
4 PPAP Project Management
Collaborate within your factory and across your supply chain with powerful Messaging and Tasks capabilities. Review and approve individual requirements and the entire PPAP package.
5 Master (Foundational) PFMEA
Build a library of failure modes by Manufacturing Process (e.g. Mill-Turn, Grinding, Plating, Deburring etc.). Automatically populate a part-number-specific PFMEA with Failure Modes, Effects, Severity, Causes, etc. from the Library and save hours of time. Ensure changes made to the Master (Foundational) PPAP are synched with each Part's PFMEA.
6 Process Flow Diagram
Build a library of failure modes by Manufacturing Process (e.g. Mill-Turn, Grinding, Plating, Deburring etc.). Automatically populate a part-number-specific PFMEA with Failure Modes, Effects, Severity, Causes, etc. from the Library and save hours of time.
7 PFMEA
Build and maintain part-number-specific PFMEAs with version control. Identify product-feature and process failure modes. Output PFMEA reports in AIAG/APQP, or AS13000 formats with a single-click.
8 Control Plan
Instantly analyze data with built-in lightning-fast reports and dashboards without expensive 3rd-party BI tools. Analyze data across work-orders. Drill-down to Part, Feature, Vendor, Inspector, Machine etc.
9 Dimensional Results
Collect factory-floor measurements from hand-held tools and CMMs, and create initial sample reports for PPAPs.
10 Measurement Systems Analysis
Perform Variable Gage R&R with configurable number of operators, parts and trials. Enjoy automated calculations and output reports with either the ANOVA or Range methods.
11 Process Capability & SPC
Automatically calculate Process Capability (Cp, Cpk) and Process Performance (Pp, Ppk) metrics for each feature. Use individuals charts and Western Electric detection rules to demonstrate control over manufacturing processes. Output capability reports for PPAP packages.
12 Delta & Revalidation PPAPs
Create and manage PPAPs for new products. Create and manage delta PPAPs for changes to engineering designs, manufacturing processes, suppliers etc. Automatically create periodic revalidation PPAPs.
CASE STUDIES
J&L Manufacturing
J&L Manufacturing provides a range of metal forming services (metal cutting, bending, stamping, welding and machining) to the automotive, hospital and other industries.
J&L did not have the manpower to support heavy PPAP documentation requirements and would turn away orders that required PPAPs. Then they found 1factory. And with 1factory, J&L was able to drop PPAP creation time from a week to just two hours.
J&L completed 168 PPAPs in the first 7 months of the year, and averages 5 PPAPs a week. More importantly nearly all PPAPs were delivered 100% accurate and complete in the first pass. They can now accept all the orders coming their way, and can grow their business.
EASY TO USE. LIGHTNING FAST.
INTUITIVE DESIGN
1factory is designed for the front-line of quality control with design inputs and ideas from our users. 1factory's intuitive navigation and best-in-class screen-designs make training a breeze. Training and full-deployment takes under two hours with no disruption to operations.
LIGHTNING FAST SPEED
1factory is engineered to be lightning-fast. We serve customers all over the world 24 hours a day, 7 seven days a week, 365 days a year. Our customers in United States, Mexico, Canada, Israel, China, South Africa, Denmark, UK, India, Malaysia, Taiwan all enjoy lightning-fast data collection and powerful real-time analytics.
SECURE AND RELIABLE
SECURITY
1factory is hosted on AWS GovCloud. The AWS GovCloud service is an isolated Amazon region designed to host sensitive data and regulated workloads, including International Traffic in Arms Regulations (ITAR) data.
All customer data transfer from client to server is encrypted over standard HTTPS/TLS 1.2, using a certificate with 2048-bit RSA public key / SHA-256 with RSA encryption. All customer data is encrypted at rest. Data (e.g. Part Numbers, Measurements etc.) are stored in an encrypted Amazon RDS instance. Drawings, Raw Material Certificates etc. are stored on encrypted Elastic Block Storage (EBS) volumes. Drawings and other documents may be additionally encrypted with individual encryption keys.
1factory complies with all NIST-800-171 requirements. 1factory also maintains a SOC2 Type 2 certification, and a copy is available upon request.
RELIABILITY
1factory has been engineered to be highly reliable, scalable and available. Over 200 million parts have been inspected with 1factory by customers in 26 countries.
1factory has delivered an uptime of >99.99% over the last 8 years. We use a third-party service to monitor system uptime, and our customers can view our uptime and availability metrics in real time.
1factory backs-up database with a daily snapshot. Files are stored on redundant hard-drives and backed up via daily snapshots.
500+ CUSTOMERS. 25+ COUNTRIES. 20+ INDUSTRIES.
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