PPAP | Production Part Approval Process | Excel Templates

What is PPAP?

→ PPAP stands for Production Part Approval Process.

→ It is essential for establishing confidence in product suppliers and their production processes.

→ This methodology is rigorously used in the automotive and aerospace industry.

→ PPAP ensures that a supplier's production process can consistently produce parts that meet the customer's specifications.

→ This method helps suppliers and manufacturers to verify that production processes consistently produce quality parts.

→ It helps to minimize the risk of defects.

→ Nowadays this method is spread to many industries beyond the automotive industry.

Table of Contents:

• What is PPAP?
• History of PPAP
• When is a PPAP required?
• Why do we need PPAP?
• What is Run at Rate in PPAP?
• What are the 5 levels of PPAP?
• 18 Documents of PPAP
• 3 Types of PPAP Approval Status
• Benefits of PPAP
• Conclusion

History of PPAP:

→ The Production Part Approval Process has its roots in the evolution of quality management systems in the automotive and manufacturing industries.

→ In the 1980s, as the global automotive market became more competitive.

→ Major American automotive companies such as General Motors (GM), Ford, and Chrysler faced increasing pressure to improve the quality of their products.

→ Defects in parts supplied to automakers were a significant problem, often leading to costly recalls and warranty claims.

→ In the early 1990s, the AIAG introduced the Production Part Approval Process as part of a broader effort to standardize supplier quality requirements across the automotive industry.

→ It became a key component of AIAG's Advanced Product Quality Planning (APQP) framework.

→ This framework ensured that products met quality standards before entering mass production.

→ This method was initially developed to address the growing complexity of vehicle manufacturing.

→ In manufacturing, thousands of parts were sourced from a global network of suppliers.

 → In response, these companies formed the Automotive Industry Action Group (AIAG) in 1982.

→ AIAG’s goal was to create standardized quality requirements for suppliers.

→ It reduced the inconsistencies and improved communication between automakers and their supply chains.

→ AIAG’s 4th edition effective June 1, 2006, is the most recent version of the PPAP.

→ PPAP was also incorporated into international standards such as ISO/TS 16949.

→ ISO/TS 16949 later became IATF 16949.

→ This global automotive quality management system standard is based on ISO 9001.

→ It requires organizations to apply PPAP as part of their quality management processes.

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When is a PPAP required?

→ A PPAP is required in several key situations, particularly when changes occur that could affect the production or quality of a part.

→ While exact requirements may vary by industry or customer.

⏩Refer to the Below-Mentioned Most Common Requirements of PPAP:

• Introduction of a new part or new product development
• Design changes or engineering change(s)
• Performance or quality.
• Changes in manufacturing location
• Use of a new or modified tooling
• Changes to production methods or processes
• Change of material or supplier
• Production suspension and restart
• Correction of a quality issue
• Change in sub-supplier or outsourcing
• Increase or decrease in production volume
• Customer-specific requirements
• Tooling: transfer, replacement, refurbishment, or additional
• It is required at the time of Tooling inactive > one year
• Parts produced at a new or additional location

Why do we need PPAP?

→ The Production Part Approval Process is required to ensure that parts or components provided by suppliers consistently meet the customer's specifications and quality standards.

→ It is an essential quality control process that helps manufacturers avoid defects, manage risks, and ensure product reliability.

⏩Refer to the Below-Mentioned Reasons for PPAP's Requirements:

• Ensuring consistency in production
• Reducing risks of defects and failures
• Improving supplier-client communication
• Verification of process capability
• Compliance with industry standards
• Managing changes and continuous improvement
• Building trust and accountability
• Avoiding costly recalls and warranty issues
• Regulatory and safety requirements
• Enabling global supply chain management

What is Run at Rate in PPAP?

→ The purpose of a Run @ Rate is to verify the supplier’s manufacturing process is capable of producing components.

→ Successful Run @ Rate means it meets Your Company's Quality Requirements, at the quoted tooling capacity, for a specified period.

→ Verification of the Run @ Rate will be at the Supplier Quality Engineer’s (SQE) discretion.

→ The supplier will be notified of the need to perform a Run @ Rate as early in the process as possible.

→ The number of components to be produced during the Run @ Rate should be sufficient to demonstrate process capability and will be predetermined by the Supplier Quality Engineer and the supplier.

→ The no. of components to be produced, may vary as per the customer's specific requirement.

→ Factors such as product complexity, shelf life, storage, cost, and single-shift vs. multiple-shift operations will be taken into consideration

What are the 5 levels of PPAP?

→ Now we will discuss the different 5 levels of PPAP.

→ Level 1: Production Warrant and Appearance Approval Report (if applicable)

→ Level 2: Warrant, product samples, and dimensional results submitted

→ Level 3: Production Warrant, product samples & complete supporting data submitted

→ Level 4: Warrant, and other requirements as defined by the customer

→ Level 5: Production Warrant, product samples, and complete supporting data (review will be at the organization's location).

18 Documents of PPAP:

→ The Production Part Approval Process involves the submission of 18 key documents.

→ These documents serve as evidence that a supplier’s production process can consistently produce parts that meet all specifications and quality standards.

→ These documents are critical in verifying the readiness of a supplier to begin mass production.

⏩18 Documents (or Elements) of PPAP:

1. Design Records
2. Authorized Engineering Change Documents
3. Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA)
5. Process Flow Diagram (PFD)
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement System Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies [Process Capability Study]
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)

👉 Read our detailed article on PPAP 18 Documents Explained With Examples

3 Types of PPAP Approval Status:

→ The PPAP has three types of approval statuses.

→ It indicates the readiness of the parts for mass production and the supplier’s compliance with the requirements.

→ These statuses allow both the customer and supplier to understand the next steps in the production process.

⏩The three PPAP approval statuses are:

1. Full Approval
2. Interim Approval
3. Rejected

01. Full Approval:

→ Full approval is granted when all PPAP documentation, samples, and production parts meet the customer’s requirements without any issues or deviations.

→ The supplier is authorized to produce the part in mass quantities.

→ The customer has no concerns regarding the part’s ability to meet the specifications, quality, and performance standards.

→ No further design or manufacturing process changes are needed, and the supplier can proceed with regular production.

→ Full Approval means everything is compliant, and mass production can begin.

02. Interim Approval:

→ Interim approval is granted when the PPAP submission has issues or incomplete documentation, but the customer still allows limited production for a specified time or quantity.

→ The supplier is allowed to temporarily produce parts, usually under specific conditions, such as a limited quantity or time frame.

→ The unresolved issues must be corrected before full approval is granted.

→ The issues could include deviations in documentation, testing, or process capability.

→ The customer may ask the supplier to provide a corrective action plan and resubmit the PPAP once the issues are resolved.

→ This status is often used when the customer needs parts urgently, even though not all aspects of the PPAP have been fully approved.

→ Interim Approval means limited production is allowed under specific conditions, with further work required to gain full approval.

03. Rejected:

→ Rejected status is assigned when the PPAP submission fails to meet the customer’s requirements.

→ The supplier is not authorized to produce the part for mass production.

→ The PPAP submission has significant issues, such as non-conformance with part specifications, incomplete documentation, or failed tests.

→ The supplier must take corrective actions to address the reasons for rejection and resubmit the PPAP for approval.

→ Production cannot proceed until a new PPAP submission is approved by the customer.

→ Rejected means the PPAP submission is not acceptable, and production cannot proceed until issues are resolved.

Benefits of PPAP:

→ PPAP helps to maintain design integrity

→ Identifies issues early for resolution

→ Reduces warranty charges and prevents the cost of poor-quality

→ Assists with managing supplier changes

→ It prevents the use of unapproved and non-conforming parts

→ Identifies suppliers that need more development

→ Improves the overall quality of the product & customer satisfaction

Conclusion:

→ The Production Part Approval Process (PPAP) is crucial for ensuring product quality and consistency in manufacturing.

→ This method helps suppliers and customers confirm that a component meets all specifications and is ready for mass production.

→ It minimizes the risk of defects and increases accountability by requiring detailed documentation, testing, and validation.

→ It also fosters communication between suppliers and manufacturers.

→ PPAP plays a vital role in maintaining high standards, particularly in industries where precision and reliability are essential, such as automotive, aerospace, and electronics.

→ A robust PPAP process ensures compliance with requirements, strengthens supplier relationships, reduces production delays, and enhances overall product reliability.

→ This systematic approach ultimately contributes to a smoother, more efficient production system and greater customer satisfaction.