PPAP (Production Part Approval Process)

 Production Part Approval Process: - PPAP is a design & manufacturing inspection process used to verify a supplier’s ability to produce a part reliably and repeatedly or a set of parts for mass production.PPAP consists of 18 -critical documents.

PPAP is typically required to produce new parts or when there is a change to the product or process:

• A new part or product.  
• Product changes/corrections: design, materials, supply, and function.
• Process changes/corrections: method, tools, location, and inspection criteria.
• Inactive tooling for more than one year.

Purpose of PPAP: -

1.          Validating supplier’s ability.

2.          Understanding customer requirements.

3.          Establishing a reliable and repeatable process & agreement.

4.          Reducing cost and having faster time to market.

5.          Maintaining expectations & compliance on both sides.

CRITICAL 18-ELEMENTS / DOCUMENTS OF PPAP: -

1. Design Records: A copy of the drawing or model provided by the customer.
2. Engineering Change Documents: Detailed description of changes of parts from previous revisions called Engineering Change Notice.
3. Customer Engineering Approval: Customer approval of sample production parts.
4. Design Failure Mode and Effects Analysis (DFMEA): Prediction of a product’s potential design failure.
5. Process Flow Diagrams: All steps in the manufacturing process including components, measurement, and inspection.
6. Process Failure Mode and Effects Analysis (PFMEA): Prediction of a potential process failure that could occur during production.
7. Control Plan: Details the plan for how quality will be implemented to ensure a stable and reliable process.
8. Measurement System Analysis (MSA): Conformance to customer’s ISO or TS standard. Usually Gage R&R for critical impact characteristics to control repeatability and reproducibility and confirmation that gages are calibrated to measure these characteristics to control measurement bias.
9. Dimensional Results: A list of every dimension noted on the ballooned drawing or model with pass/fail assessment.
10. Material / Performance Test Results: Summary of every test performed on the part, usually in the form of DVP&R (Design Verification Plan and Report).
11. Initial Process Studies: This shows that critical processes are reliable. Includes SPC (statistical process control) charts.
12. Qualified Laboratory Documentation: All industry certifications for validation testing.
13. Appearance Approval Report (AAR): Customer approval on final product appearance including color, texture, fit, and more.
14. Sample Product: Sample from the initial production run.
15. Master Sample: Sample part signed off by customer and supplier.
16. Checking Aids: Detailed list of all tools used to inspect and measure parts.
17. Records of Compliance with Customer-Specific Requirements: List of customer’s specific requirements for the PPAP process.
18. Part Submission Warrant (PSW): Summary of the entire PPAP submission.

PPAP requirements are typically distinguished by level as follows: -

            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. Complete documentation.

PPAP Retention and Submission Requirements Table
Requirements		Level 1	Level 2	Level 3	Level 4	Level 5
1. Design Record		R	S	S	*	R
	- for proprietary components/details	R	R	R	*	R
	- for all other components/details	R	S	S	*	R
2. Engineering Change Documents		R	S	S	*	R
3. Customer Engineering Approval		R	R	S	*	R
4. Design FMEA		R	R	S	*	R
5. Process Flow Diagrams		R	R	S	*	R
6. Process FMEA		R	R	S	*	R
7. Control Plan		R	R	S	*	R
8. Measurement System Analysis		R	R	S	*	R
9. Dimensional Results		R	S	S	*	R
10. Material, Performance Test Results		R	S	S	*	R
11. Initial Process Studies		R	R	S	*	R
12. Qualified Laboratory Documentation		R	S	S	*	R
13. Appearance Approval Report		S	S	S	*	R
14. Sample Report		R	S	S	*	R
15. Master Sample		R	R	R	*	R
16. Checking Aids		R	R	R	*	R
17. Records of Compliance w/ Customer-Specific Requirements		R	R	S	*	R
18. Part Submission Warrant (PSW) | Bulk Material Checklist		S	S	S	*	R
S = Organization must submit to the customer and retain a copy of records or documentation items at appropriate locations. R = Organization must retain at appropriate locations and make available to the customer upon request. * = Organization must retain at the appropriate location and submit to the customer upon request.