Never Stop Learning….

PPAP - PRODUCTION PART APPROVAL PROCESS

What is PPAP

• Standard used to formally reduce risks prior to product or service release

in a team oriented manner using well established tools and techniques

• Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from

the Big 3 - Ford, Chrysler, and GM

• PPAP has now spread to many different industries beyond automotive

Purpose of PPAP

• Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization
• To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate

When PPAP is required

• New part
• Engineering change(s)
• Tooling: transfer, replacement, refurbishment, or additional
• Correction of discrepancy
• Tooling inactive > one year
• Change to optional construction or material
• Sub-supplier or material source change
• Change in part processing
• Parts produced at a new or additional location

​

Prototype

Pilot Lot

Mass Production

PPAP Levels of Submission

Level 1 – Part Submission Warrant (PSW) only submitted to the customer

Level 2 – PSW with product samples and limited supporting data

Level 3 – PSW with product samples and complete supporting data

Level 4 – PSW and other requirements as defined by the customer

Level 5 – PSW with product samples and complete supporting data

available for review at the supplier’s manufacturing location

Production Run @ Rate

• The purpose of a Run @ Rate is to verify the supplier’s manufacturing

process is capable of producing components that meet customer

quality requirements, at quoted tooling capacity, for a specified period of time

.

Official Production Part Approval Process (PPAP) requirements

1. Design Records
2. Engineering Change Documentation
3. Customer Engineering Approval
4. Design Failure Mode and Effects Analysis (DFMEA)
5. Process Flow Diagram
6. Process Failure Mode and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement System Analysis Studies (MSA)
9. Dimensional Results
10. Records of Material / Performance Tests
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer Specific Requirements
18. Part Submission Warrant

1. Design Records

• Bill of material
• Assembly drawing
• Part drawing
• Material specification
• Engineering & Testing specifications.

2. Engineering Change Documentation

• If the PPAP is being required due to a request for a change to a part or product,

the documentation requesting and approving the change must be included

in the PPAP package.

• The Engineering Change Notice (ECN), which must be approved by the

customer engineering department.

3. Customer Engineering Approval

• If required, pre-PPAP samples are ordered by the customer for onsite testing.

The samples must be production intent and ship with a waiver so that testing can be done.

When testing is complete, the test engineers will provide an approval form for inclusion

in the PPAP submission.

4. Design Failure Mode and Effects Analysis (DFMEA)

• It is a cross-functional activity that examines design risk by exploring the possible

failure modes and their effects on the product or customer and their probability to occur.

5. Process Flow Diagram

6. Process Failure Mode and Effects Analysis (PFMEA)

• The Process Flow Diagram outlines the entire process for assembling the component

or final assembly in a graphical manner. The process flow includes incoming material,

assembly, test, rework and shipping.

• PFMEA reviews all of the steps in the production process to identify any potential

process quality risk and then document the applied controls.

• The PFMEA is also a living document and should be updated even after the

product is in normal production.

7. Control Plan

8. Measurement System Analysis Studies (MSA)

• The control plan is an output from the PFMEA.
• The Control Plan lists all product Special Characteristics and inspection

methods required to deliver products that continually meet the customer

quality requirements.

• Measurement system analysis (MSA) studies will include gauge

repeatability & Reproducibility(GR&R)  studies on measurement equipment

used during assembly or quality control checks.

• Calibration records for all gages and measurement equipment must be included.

9. Dimensional Results

10. Records of Material / Performance Tests

• Dimensional layout of sample parts is required to validate the product meets the

print specifications.

• The samples should be randomly selected from a significant production run usually

at least 30 pieces.

• Each dimension on the drawing is measured on the final assembly to make sure that

it falls within specification.

• The results are recorded in a spreadsheet and included within the PPAP submission.

• This element should contain a copy of the Design verification plan and report (DVP&R)  
• The DVP&R is a summary of every validation test performed on the part.
• It should list each and every test performed, a description of how the test

was performed, and the results of each test.

• This section may also include copies of all the certification documents

for all materials (steel, plastics, etc.) listed on the prints. The material certification

shall show compliance to the specific call on the print.

11. Initial Process Studies

12. Qualified Laboratory Documentation

• initial process studies will be done on all the production processes and will include 

Statistical Process Control (SPC)charts on the critical characteristics of the product.

• These studies demonstrate that the critical processes are stable, demonstrate

normal variation and are running near the intended nominal value. 

• Qualified laboratory documentation consists of the industry certifications

for any lab that was involved in completing validation testing.

• This could be for an in-house test lab or any offsite contracted test

facilities that were used for validation or material certification testing.

13. Appearance Approval Report

14. Sample Production Parts

• The Appearance Approval Inspection (AAI) is applicable for components

affecting appearance only.

• This report verifies that the customer has inspected the final product and

it meets all the required appearance specifications for the design.

• The appearance requirements could include information regarding

the color, textures, etc.

• Sample production parts are sent to the customer for approval and are

typically stored at either the customer or supplier’s site after the product

development is complete.

• A picture of the production parts is usually included in the PPAP documentation

along with documentation regarding the location that the parts are being stored.

15. Master Sample

16. Checking Aids

• A master sample is a final sample of the product that is inspected and signed

off by the customer.

• The master sample part is used to train operators and serves as a benchmark

for comparison to standard production parts if any part quality questions arise.

• This is a detailed list of checking aids used by production. It should include

all tools used to inspect, test or measure parts during the assembly process.

• The list should describe the tool and have the calibration schedule for the tool.
• Checking aids may include check fixtures, contour, variable and attribute gages,

models or templates.

• MSA may be required for all checking aids based on customer requirements.

17. Customer Specific Requirements

18. Part Submission Warrant

• This element of the submission package is where any special customer

requirements are contained.

• For bulk materials, the customer specific requirements shall be recorded

on the “Bulk Material Requirements Checklist”.

• The Part Submission Warrant (PSW) form is a summary of the entire PPAP submission. 
• A PSW is required for each of part number unless otherwise stated by the customer.
• The PSW includes:
• The reason for submission (design change, annual re-validation, etc.)
• The level of documents submitted to the customer
• Declaration of part conformity to customer requirements
• A section provided for any required explanation or comments
• Supplier authorized person signature along with contact information
• An area for the customer to indicate disposition of the PPAP

​

​