What are PPAP 18 Documents?
→ The Production Part Approval Process has eighteen standard documents.
→ It is also known as the 18 Elements of PPAP.
→ These documents serve as evidence that a part or component meets all customer specifications and requirements before mass production.
→ The PPAP is a standardized procedure used in the automotive and aerospace industries.
→ The 18 elements ensure comprehensive verification and accountability.
→ It also helps to establish confidence in the production quality and consistency before scaling up to mass production.
Table of Contents:
- What are PPAP 18 Documents?
- Purpose of the PPAP 18 Documents
- The Significance of PPAP Documents in Manufacturing
- PPAP Process Flowchart
- Five Levels of PPAP
- PPAP 18 Documents
- Benefits
- Conclusion
Purpose of the PPAP 18 Documents:
→ The Eighteen Documents of PPAP serve as a comprehensive validation process.
→ This process ensures all aspects of part design, production, quality control, and consistency have been addressed before mass production begins.
→ These documents are crucial for verifying that the supplier’s production process is capable of consistently producing parts that meet the customer's quality standards and specifications.
→ The Eighteen Documents of PPAP each serve a specific purpose.
→ All documents are aimed that a part meets all quality and production standards before full-scale manufacturing.
→ These documents work together to verify that the part meets all functional, aesthetic, and durability requirements.
→ It ensures that the production process is reliable and can maintain quality at scale.
→ This structured approach helps reduce the risk of defects, minimizes delays, and establishes a foundation for long-term quality and trust between suppliers and customers.
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The Significance of PPAP 18 Documents:
→ PPAP documents are crucial for different reasons in manufacturing.
→ Now we will discuss some of the key reasons for the same.
⏩Quality Assurance:
→ It ensures that the manufacturing process can consistently produce parts that meet all specifications.
→ It also ensures a consistent approval process between the customer and supplier.
⏩Risk Mitigation:
→ Thoroughly evaluating the production process.
→ That helps to identify and resolve potential issues early.
→ It reduces the risk of costly errors and recalls and helps ensure on-time delivery.
⏩Supplier Confidence:
→ A comprehensive PPAP package demonstrates that the supplier is capable of delivering high-quality, reliable parts.
→ By incorporating PPAP into their processes, suppliers achieve higher standards of quality.
→ Also, build stronger relationships with customers through stable production quality performance and on-time delivery.
⏩Regulatory Compliance:
→ PPAP is often required by regulatory bodies and industry standards to ensure that products meet necessary safety and quality criteria.
PPAP Process Flowchart:
→ We can achieve PPAP compliance by proper preparation and planning.
→ For suppliers, this involves understanding our specific requirements and the industry standards.
⏩Key Steps for PPAP Compliance:
- Identify Requirements
- Assemble a Team
- Create a Plan
- Training
Five Levels of PPAP:
→ PPAP submissions are categorized into five different levels.
→ Each level has different requirements for PPAP sign-off based on the complexity and criticality of the part.
⏩Key Levels of PPAP Requirements:
→ Level 1: Part Submission Warrant (PSW) only.
→ Level 2: PSW with limited supporting documentation, such as dimensional results and material test results.
→ Level 3: PSW with complete supporting documentation, including all 18 elements.
→ Level 4: PSW and other requirements as specified by the customer.
→ Level 5: PSW with complete supporting documentation, plus a review at the supplier’s manufacturing location.
PPAP 18 Documents:
→ The PPAP involves the submission of 18 key documents.
→ These documents are critical in verifying the readiness of a supplier to begin mass production.
⏩The List of PPAP 18 Documents:
- Design Records
- Authorized Engineering Change Documents
- Engineering Approval, if required
- Design Failure Modes and Effects Analysis (DFMEA)
- Process Flow Diagram (PFD)
- Process Failure Modes and Effects Analysis (PFMEA)
- Control Plan
- Measurement System Analysis (MSA)
- Dimensional Results
- Records of Material / Performance Test Results
- Initial Process Studies
- Qualified Laboratory Documentation
- Appearance Approval Report (AAR)
- Sample Production Parts
- Master Sample
- Checking Aids
- Customer-Specific Requirements
- Part Submission Warrant (PSW)
- Now we will learn about all documents in detail.
01. Design Records or Drawing:
→ This includes the part drawings, CAD files, and specifications that define the part's design.
→ A design record is either given by the customer with the purchase order (PO) or developed by the supplier.
→ The supplier must submit a copy of the design records that match the customer’s specifications.
→ If the supplier created the design, they must provide all details.
→ If the supplier is responsible for designing this is a released drawing in the supplier’s release system.
02. Authorized Engineering Change Documents:
→ This document is required when there have been any engineering changes made to the part after the original design.
→ It serves as evidence that any changes to the design have been authorized and approved by the customer.
→ These documents show a detailed description of the change.
→ Usually, this document is called an “Engineering Change Notice (ECN)”, but it may be covered by the customer PO or any other engineering authorization.
03. Engineering Approval, if required:
→ Some customers require formal approval of prototype parts or initial production parts.
→ This document provides the customer’s written approval of the part from an engineering perspective.
→ Engineering approval is usually the trial taken with production parts and takes an approval for production plant from the customer.
→ A "temporary deviation" is an example of engineering approval.
04. Design Failure Modes and Effects Analysis (DFMEA):
→ This is an analysis that identifies potential failure modes in the design of the part and their possible effects.
→ The DFMEA helps the supplier to plan mitigation or corrective actions to prevent those failures, ensuring that the design is robust.
→ A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed off by supplier and customer.
→ The design maker is responsible for (DFMEA).
05. Process Flow Diagram (PFD):
→ PFD is a visual representation of the entire production process, from receiving raw materials to the delivery of the finished product.
→ The PFD outlines every step in the process and helps to identify potential quality risks and critical control points.
→ It is also known as a flow chart.
06. Process Failure Modes and Effects Analysis (PFMEA):
→ This is an analysis that identifies potential failure modes within the production process and evaluates their effects on product quality.
→ The PFMEA helps the supplier to establish controls and corrective actions to address potential risks in the production process.
→ A copy of the PFMEA reviewed and signed off by the supplier and customer.
→ The PFMEA follows the Flow Chart's steps and indicates "what could go wrong" during the operation and assembly of each component till the product is dispatched.
07. Control Plan:
→ The control plan is a written document that includes all the controls that will be used during production to ensure the product meets quality requirements.
→ It includes details on inspection methods, testing, and process monitoring to prevent defects and ensure consistency.
→ A copy of the Control Plan should be reviewed and signed off by the supplier and customer.
→ The Control Plan follows the PFMEA steps and provides more details on how the "potential issues" are checked in the different stages of the process.
08. Measurement System Analysis (MSA):
→ MSA evaluates the measurement systems used in the quality control process to ensure that they are accurate, repeatable, and reliable.
→ The measurement system is a combination of appraisers, tools, gauges, and equipment.
→ This includes studies such as Gauge R&R (Repeatability and Reproducibility).
→ This study is required for critical or high-impact characteristics.
→ It gives confirmation that the measurement system can measure these characteristics of the product.
09 Dimensional Results:
→ Dimensional results are the results of dimensional inspections conducted on the product.
→ It verifies that all the parts' dimensions match the design records' specifications.
→ Typically, this is done on a sample size of parts from the production run.
→ A list of every dimension noted on the ballooned drawing.
→ This list shows the product characteristics, specification, measurement results, and the assessment showing if this dimension is "ok" or "not ok".
10. Records of Material/Performance Test Results:
→ This includes test results and certification documents to prove that the materials used in production meet the necessary specifications.
→ If the product requires performance testing, those results are also included.
→ It may cover chemical composition, hardness, tensile strength, etc.
11. Initial Process Studies:
→ This document contains the results of process capability studies to ensure that the production process is capable of consistently producing parts that meet specifications.
→ Typically, statistical process control methods such as Cp and Cpk are used to demonstrate process capability.
→ The intent is to demonstrate that critical processes have stable variability and that are running near the intended nominal value.
→ It is also known as the Process Capability Study.
12. Qualified Laboratory Documentation:
→ It is evidence that any testing was conducted by a qualified or accredited laboratory.
→ This certification ensures that testing was performed by a recognized and certified entity, verifying the reliability of the test results.
13. Appearance Approval Report (AAR):
→ If the part has specific appearance requirements (such as color, texture, and finish) then this document is submitted to show that the part's appearance has been approved by the customer.
→ The AAR ensures the visual aspects of the product meet the customer’s standards.
→ A copy of the AAR (Appearance Approval Report) form signed by the customer.
14. Sample Production Parts:
→ These are physical samples of the production parts that are provided to the customer for inspection and approval.
→ The samples help verify that the supplier can produce parts that meet all design and quality specifications under normal production conditions.
→ The PPAP package usually shows a picture of the sample and where it is kept.
15. Master Sample:
→ A "master" sample is a physical part that is kept as a reference standard by both the supplier and the customer. It serves as a control sample against which future production parts can be compared to ensure consistency and quality.
→ A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections.
→ After the defined interval master sample should be replaced and approved by the customer periodically.
16. Checking Aids:
→ It is a detail of any tools, fixtures, gauges, or checking aids used during the inspection or quality verification process.
→ This ensures that the tools used to verify part quality are properly calibrated and capable of ensuring accurate measurements.
17. Customer-Specific Requirements:
→ Some customers may have additional requirements beyond the standard PPAP documents.
→ This section addresses any unique requirements a specific customer may have, such as special reporting, data formats, or additional tests.
→ In general, it should be the length, width, height, weight, GSM, or any technical value depending on the product.
18. Part Submission Warrant (PSW):
→ The PSW is the final summary document that certifies that the supplier has met all customer requirements for the part.
→ It is the official approval form that confirms that the PPAP submission is complete and that the supplier is ready for production.
→ Both the supplier and customer sign off on this document to confirm the agreement.
→ This is the form that summarizes the whole PPAP package.
→ This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer.
→ There is a section that asks for "results meeting all drawing and specification requirements: "yes/no" refers to the whole package.
Benefits:
- Improved Product Quality
- Enhanced Process Control
- Increased Customer Confidence
- Reduced Production Costs and Waste
- Better Supplier Communication and Collaboration
- Continuous Improvement
- Risk Management
- Problem Prevention
- Streamlined Product Launches
Conclusion:
→ The PPAP's eighteen documents provide a comprehensive framework to ensure product quality and process reliability.
→ By implementing these documents, manufacturers proactively identify and mitigate risks.
→ Also, we can establish robust process controls and enhance communication with suppliers and customers.
→ This leads to better product quality and reduced production costs.
→ Implementing these documents, we can strengthen customer confidence and drive continuous improvement.
→ The PPAP approval is essential for achieving long-term success and competitiveness in industries where quality and precision are paramount.
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