Production Part Approval Process | PPAP process | PPAP Levels

PPAP (Production Part Approval Process) is a quality core tool that consists of 18 documents used by the automotive industries for establishing confidence in product suppliers and their manufacturing processes.

The production part approval process manual is developed by the Automotive Industry Action Group (AIAG) and it is an important part of the APQP planning process.

Production Part Approval Process (PPAP) is one of the very important core tools of the IATF 16949:2016 standard and is triggered in the fourth phase of the APQP process (Product and Process Validation phase).

The five Quality Core Tools of IATF 16949 standard are:

• APQP-Advanced Product Quality Planning
• FMEA- Failure Mode Effect Analysis
• PPAP-Production Part Approval Process
• MSA-Measurement System Analysis
• SPC-Statistical Process Control

Production Part Approval Process Scope

Earlier PPAP process was being utilized by the automotive and aerospace industries only. Now PPAP is being used by various non-automotive industries also to improve product and process quality, communication, and enhance customer satisfaction.

PPAP documentation is applicable to production and service commodities, including bulk materials. For bulk, raw or indirect material, it is the customer’s decision on whether PPAP is required.

When PPAP submission is required?

Production part approval is usually required before the first production shipment of part in the following conditions/situations.

• For new product development.
• Any change or correction of discrepancy on a previously submitted product.
• Any product modification by an ECN process (e.g. due to change in design, specifications, material, etc).
• Production from new or modified dies, tools (except perishable tools), molds, patterns, etc.
• Production following any change in methods or process of manufacturing.
• Any change in machine and raw material.
• Any change on the subcontractor or sub-suppliers parts/materials or services.
• When the production tooling/machinery is inactive for production volume up to 12 months or more.

PPAP Levels

The PPAP quality has five submission levels which are listed below:

• Level 1: Part Submission Warrant (PSW) only with appearance report (if applicable).
• Level 2: PSW with product samples and limited supporting documents.
• Level 3: PSW with product samples and complete supporting documents.
• Level 4: PSW and other specific requirements as defined by the customer.
• Level 5: PSW with product samples and complete supporting documents to be retained at supplier location for review.

PPAP Level 3  is the by default level and we can close the PPAP process submission at level 3 if no any specific requirements defined by the customer.

PPAP Documents | PPAP Elements

PPAP has 18 documents as per IATF 16949:2016 requirements and all of these are listed below:  

1. Design Records or documents (customer’s part drawing or specification).
2. Engineering Change Note- Any authorized engineering change documents not yet incorporated in the design record but incorporated in the part.
3. Customer Engineering Approval
4. DFMEA-Design Failure Mode and Effects Analysis
5. PFD-Process Flow Diagram
6. PFMEA-Process Failure Mode and Effects Analysis
7. Control Plan
8. MSA-Measurement System Analysis (Gage R&R studies)
9. Dimensional Results (Product Layout Inspection as per customer approved drawing)
10. Performance Tests Reports-for parts with color, grain, or surface requirements.
11. Initial Process Capability Studies (SPC Studies)
12. Qualified Laboratory Documentation
13. Appearance Approval Report
14. Production Samples parts
15. Master Sample
16. Checking Aids – used in inspecting or testing
17. Customer Specific Requirements.
18. Part Submission Warrant-The Part Submission Warrant (PSW) is the summarise documents of the entire PPAP submission.

PPAP Process Requirements

Significant Production Run: Parts for submission must come from a significant production run. This production run shall be from  1 hour to 8 hours or one shift production, and with the specific production quantity to total 300 parts minimum unless otherwise defined by the authorized customer quality representative.

Production parts are manufactured at the production site using existing production tooling, gauging, process, materials, and operators from the production environment.

During the production trial run, Control Plan and Process Flow Chart must be available on the production site and to be followed strictly to meet the customer’s requirements.

PPAP production trial run is conducted or triggered in the fourth phase of the APQP process.

Production Part Approval Process Benefits

• Provide a better quality of products and services.
• Enhance customer satisfaction level.
• Reduce cost due to poor quality and warrant return.
• Improve communication between internal and external customers.
• Minimize the risk of failure of the APQP process.

Production Part Approval Process (PPAP) Vs APQP

PPAP is an important component of the APQP planning process. The better results/output of the PPAP manufacturing process generally depends on the effective Advanced Product Quality Planning process.

The Production Part Approval Process’s failure in meeting the client’s requirements means that the Advanced Product Quality Planning process is not working effectively.

Effectiveness or test of both PPAP and APQP process is measured during production trial run. If the non-conformance or defects are observed in finished product samples, then the CFT of an organization must focus on finding out the root cause to plug the gap in PPAP and APQP process.

PPAP related questions asked in the interview

Some of the important questions that are often asked in an interview are:

• Q1: What is PPAP?
• Q2: What is the purpose or objective of PPAP?
• Q3: How many documents/elements are in PPAP?
• Q4: What are the 18 documents/elements of PPAP?
• Q5: How many levels of PPAP submission?
• Q6: What are the five levels of the PPAP process?
• Q7: What is the default level of PPAP?
• Q8: Why is PPAP submission required?
• Q9: When is PPAP submission required?
• Q10: What is a Significant production run?
• Q11: PPAP production run triggered in which phase of the APQP process?

Ans: To know the answers to all the above questions, read the article thoroughly.