The Production Part Approval Process (PPAP) is a standardized quality framework used primarily in the automotive supply chain and other highly regulated manufacturing sectors. This formal methodology ensures that a supplier’s manufacturing process can consistently produce parts meeting all of a customer’s engineering design specifications. The process acts as a rigorous gateway, providing objective evidence that the supplier understands all requirements before committing to high-volume mass production.
Defining the Production Part Approval Process (PPAP)
PPAP is a comprehensive documentation package designed to verify the capability of a supplier’s production process. The core objective is to confirm that the established manufacturing method can consistently produce parts meeting all requirements during an actual production run at the quoted rate. This verification involves a detailed review of the supplier’s systems, tooling, and documentation to ensure process stability and mitigate risks associated with new or changed parts.
The underlying framework for PPAP is standardized and governed by the Automotive Industry Action Group (AIAG) PPAP Manual. This industry standard dictates the minimum documentation and submission requirements necessary for a supplier to gain approval to ship production quantities. Successfully completing PPAP confirms that the supplier is capable of mass-producing the part with the required quality and reliability.
Key Situations Requiring PPAP Submission
A new or revised PPAP submission is mandatory whenever specific changes occur that could potentially affect the fit, form, function, performance, or material of a production part. The most common trigger for a full PPAP submission is introducing a completely new part or product to the manufacturing line. This initial submission validates the entire process.
Modifications to the manufacturing environment or process also require review. This includes relocating production to a different facility, utilizing new or significantly modified tooling, or altering the current manufacturing method. A change in the source of a sub-supplier’s material or component also necessitates a new submission to verify consistent quality.
Engineering design changes or revisions to the official customer drawing require a PPAP submission to confirm the manufacturing process meets updated specifications. If tooling becomes inactive for twelve months or more, a submission is required upon restarting production to re-validate process stability. The customer ultimately retains the authority to dictate when a new submission is required.
The 18 Required Elements of a PPAP Submission
The PPAP package is composed of eighteen distinct elements, each providing objective evidence that the supplier has met all customer requirements. While the complexity and risk determine which elements are submitted to the customer, all eighteen must be completed and retained by the supplier.
A. Design Records
This element consists of the official customer drawing or three-dimensional data model, including a record of the part’s mass. The design record must be clearly marked with the customer’s part number, revision level, and date, serving as the foundational reference for all dimensional and material specifications.
B. Engineering Change Documents
This documents any authorized changes to the product design that occurred after the initial release of the design record. These records, such as an Engineering Change Notice, must show the authorized sign-off allowing the change to be incorporated into the production part.
C. Customer Engineering Approval
This provides proof that the customer has formally approved the supplier’s prototype samples or initial production run parts. This approval is often tied to an engineering trial or pilot build and signifies initial customer acceptance of the design.
D. Design Failure Mode and Effects Analysis (DFMEA)
The DFMEA is a systematic analytical tool used to assess the potential failure modes of the product design itself. It evaluates the severity, occurrence, and detection of potential design flaws before production begins.
E. Process Flow Diagram
This diagram visually maps out every step of the manufacturing process, from receiving raw materials to shipping the finished product. It includes all operations, transportation, inspection, and rework loops, providing a high-level view of the entire production sequence.
F. Process Failure Mode and Effects Analysis (PFMEA)
The PFMEA analyzes the potential ways the manufacturing process could fail to produce a conforming part. This analysis focuses on process steps identified in the flow diagram and assigns risk prioritization to potential causes of defects.
G. Control Plan
The Control Plan documents the methods used to control the manufacturing process and ensure product quality. It lists all process characteristics and product characteristics, along with the specific control methods, specifications, and reaction plans for non-conformance.
H. Measurement System Analysis Studies (MSA)
MSA studies, such as Gage Repeatability and Reproducibility (Gage R&R), confirm that the measurement equipment is accurate and reliable enough for the intended application. This ensures that any measured variation is due to the process and not the gauge itself.
I. Dimensional Results
This record provides the actual measured values for every dimension and characteristic specified on the design record and Control Plan. The results are typically taken from a specified number of parts from the initial production run to demonstrate dimensional compliance.
J. Material/Performance Test Results
This element includes documentation proving that the materials used meet the specified chemical, physical, or metallurgical requirements. It also contains results from performance tests, such as durability or functional testing, required by the design record.
K. Initial Process Studies
Statistical evidence is presented here to demonstrate that the manufacturing process is capable of meeting the required specifications for all special characteristics. This typically involves calculating process capability indices, like Cpk and Ppk, based on data collected from the initial production run.
L. Qualified Laboratory Documentation
This documentation certifies the competence of any laboratory, internal or external, that performed the required material or performance testing. It includes the laboratory’s scope of accreditation and official certifications, ensuring the integrity of the test results.
M. Appearance Approval Report (AAR)
The AAR is required for any part that has aesthetic requirements, such as color, texture, or finish. This signed report confirms that the customer has formally approved the look and feel of the production part.
N. Sample Parts
These are the physical parts produced during the significant production run that are submitted to the customer for review. These samples are representative of the parts that will be shipped in volume.
O. Master Sample
A Master Sample is a physical part, retained by both the supplier and the customer, that is signed off and dated by the customer. It serves as a fixed standard against which future production parts can be compared in case of a dispute or quality concern.
P. Checking Aids
This element includes documentation that verifies the accuracy of any specialized gauges, fixtures, or measurement templates used to inspect the part. It confirms that the checking aids are calibrated and capable of accurately measuring the required characteristics.
Q. Customer-Specific Requirements
Beyond the standard eighteen elements, customers often have unique documentation or process requirements. This section ensures that the supplier has addressed and provided records of compliance for all such additional mandates.
R. Part Submission Warrant (PSW)
The PSW is the final, summary document that formally certifies that the entire PPAP submission is complete and that the parts comply with all customer requirements. Signed by an authorized supplier representative, it includes the reason for submission and the level of documents submitted.
Understanding the PPAP Submission Levels
The PPAP process utilizes five standardized submission levels to define how documentation is presented to the customer for review. These levels offer flexibility based on the part’s complexity, supplier history, and risk, determining the amount of data the customer reviews versus the amount the supplier retains.
The five submission levels are:
- Level 1: Requires submission of only the Part Submission Warrant (PSW) to the customer. All other supporting data is retained at the supplier’s location. This is typically used for low-risk parts.
- Level 2: A limited submission requiring the PSW, product samples, and limited supporting data, such as dimensional results and material test reports.
- Level 3: The most common requirement, requiring the PSW, product samples, and the complete supporting data for a full review. This ensures the customer receives extensive evidence of process capability.
- Level 4: Requires the PSW and any other specific requirements defined and agreed upon by the customer.
- Level 5: The most rigorous level, requiring the PSW, product samples, and the complete supporting data to be made available for review at the supplier’s manufacturing location, often involving an on-site audit.
PPAP Status and Record Retention
Once the customer reviews the submitted PPAP package, they issue one of three primary approval statuses.
The Approved status grants final, full approval, allowing the supplier to begin shipping production parts with no restrictions. This status indicates the process has been fully validated and meets all specifications.
An Interim Approval may be granted if minor issues are present that do not prevent the part from being used. This status allows for limited production and shipment for a defined time or quantity, contingent upon the supplier submitting an action plan to resolve the outstanding issues. The process must be corrected and resubmitted to achieve Approved status.
A Rejected status is issued when the PPAP package or the parts do not meet customer requirements, and the parts cannot be shipped. The supplier must immediately correct the process, resolve the non-conformances, and submit a completely revised PPAP package for re-evaluation.
Suppliers are required to retain all PPAP documentation for the life of the part program plus one calendar year, or as specified by the customer. Maintaining this documentation is an ongoing quality requirement, ensuring that process compliance can be verified at any point during the part’s active production life.