During the Start of Production (SoP) phase, each organization takes part in the Production Part Approval Process – PPAP.
It’s one of the stages of the delivered product approvals, apart from approving the production process and validating the manufactured product, which is supervised by the engineering department. The main goal of PPAP is:
- actions and responsibilities defining to ensure correct application of the part approval process in the pre-launch phase and current production
- verification that all Customer requirements have been fully understood by the Supplier
- Verification that the off-Tool off Process (OTOP) will enable the production of parts compliant with these requirements.
- verification of the passage of tests carried out for confirmation within the prescribed time,
- verification that the final production process in the final location (OTOP) retains all functional, reliability, dimensional and aesthetic characteristics.
Sometimes is said that PPAP is a summary of our work as a supplier and is the culmination of Advanced Product Quality Planning (APQP).
From the IATF point of view, the requirement that includes PPAP is included in section 8.3.4.4 – Product approval process. One of the important things mentioned in this section is the information regarding completion of the approval process of externally supplied components (often referred to as “Buy components”) prior to submission of the final product.
Recommendation in such case is that the submission of parts should take place after internal or external verification of the manufacturing process directly by the customer representative (SQE, STA ect).
PPAP elements
During the PPAP, the organization must submit 18 elements to the customer, which guarantee that the supplier is able to meet the appropriate quality and quantity requirements for the manufactured product. All of them are listed below:
- Design Records
- Engineering Change Documents
- Customer Engineering Approval
- Design FMEA
- Process Flow Diagrams
- Process FMEA
- Control Plan
- Measurement System Analysis Studies MSA
- Dimensional Results
- Records of Material / Performance Test Results
- Initial Process Studies
- Qualified Laboratory Documentation
- Appearance Approval Report
- Sample Production Parts
- Master Sample
- Checking Aids
- Customer Specific Requirements
- Part Submission Warrant (PSW)
Depending on the submission of parts required level (from 1 to 5) there are two approaches which are used:
- are submit to the client and in parallel supplier keeps copies of documents and samples in the appropriate place or
- supplier keeps copies of documents and samples in a suitable place and make them available to the customer upon request
If the submission level is unknown, please contact the customer – the default level is level 3. In addition, customer approval is required before production reflecting the maximum quantities for the production ramp-up curve.
Production parts preparation
Parts for approval must be taken from a significant production run, ie 1 hour to 8 hours and a minimum of 300 consecutive parts, unless otherwise agreed in writing with the customer. Additionally, the production process should be OTOP (off-tool off-process) status, which means that it should be final and should be in a definitive production location.
It is also worth remembering that when submitting parts dedicated to PPAP to the client, we should obtain approval for all sub-components included in the manufactured product.
