What is PPAP? (Production Part Approval Process):
→ PPAP is the Production Part Approval Process.
→ It is a very important tool for establishing confidence in product suppliers and their production processes."
→
ISO 9001:2015 and
IATF 16949:2016is used to formally reduce risks prior to product or service release, in a team-oriented manner, using well-established tools and techniques.
→ Initially developed by AIAG (Automotive Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM
→ AIAG’s 4th edition effective June 1, 2006, is the most recent version of the PPAP.
→ PPAP has now spread to many different industries beyond the automotive and it provides evidence that all customer design record and specification requirements are properly understood by the organization.
→ To demonstrate that the manufacturing process has the potential to produce the product that consistently meets all requirements during an actual production run at the quoted production rate.
When is PPAP Required?
→ PPAP is required at the time of new product development
→ It is required at the time of Engineering change(s)
→ Tooling: transfer, replacement, refurbishment, or additional
→ Correction of discrepancy
→ It is required at the time of Tooling inactive > one year
→ Change to optional construction or material
→ Sub-supplier or material source change
→ Parts produced at a new or additional location
Benefits of PPAP Submission:
→ PPAP helps to maintain design integrity
→ Identifies issues early for resolution
→ Reduces warranty charges and prevents the
Cost of the Poor Quality→ Assists with managing supplier changes
→ It prevents the use of unapproved and nonconforming parts
→ Identifies suppliers that need more development
→ Improves the overall
Quality of the Product & customer satisfaction
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 quoted tooling capacity, for a specified period of time.
→ 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.
→ And 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, it 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?
→ 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).
PPAP Documents with Excel Templates:
18 Documents or Elements of PPAP:
- 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 [Process Capability Study]
- Qualified Laboratory Documentation
- Appearance Approval Report (AAR)
- Sample Production Parts
- Master Sample
- Checking Aids
- Customer-Specific Requirements
- Part Submission Warrant (PSW)
➨ Note: For each level, full APQP is required as per the customer's requirement. The PPAP level simply indicates which elements you submit, and which you retain at your site.
[1] Design Records or Drawing:
→ A design record is a copy of the drawing either it is given by the customer with the purchase order (PO) or developed by the supplier.
→ If the supplier is responsible for designing this is a released drawing in the supplier’s release system.
[2] Authorized Engineering Change Documents:
→ Authorized Engineering Change Documents is a document that shows a detailed description of the change.
→ Usually, this document is called “Engineering Change Notice (ECN)”, but it may be covered by the customer PO or any other engineering authorization.
[3] Engineering Approval, if required:
→ 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.
[4] Design Failure Modes and Effects Analysis (DFMEA):
→ A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed-off by supplier and customer.
→ Design maker is responsible for (DFMEA)
[5] Process Flow Diagram (PFD):
→ A copy of the PFD, indicating all steps and sequences of operation, including incoming components to the final part, dispatched.
It is also known as a flow chart.
👉 Download PFD Excel Template
[6] Process Failure Modes and Effects Analysis (PFMEA):
→ A copy of the PFMEA reviewed and signed-off by the supplier and customer.
→ The PFMEA follows the Flow Chart's steps, and indicate “what could go wrong” during the operation and assembly of each component till product dispatched.
👉 Download PFMEA Excel Template
[7] Control Plan:
→ A copy of the Control Plan reviewed and signed-off by supplier and customer.
→ The Control Plan follows the PFMEA steps and provides more details on how the “potential issues” are checked in the incoming quality, assembly process or during inspections of finished products until the dispatched final product.
👉 Download Control Plan Excel Template
[8] Measurement System Analysis (MSA):
→ Measurement System Analysis (MSA) usually contains the Gage R&R Study for critical or high impact characteristics.
→ It gives confirmation that the measurement system (an instrument and appraiser) is able to measure these characteristics of the product.
👉 Download GRR Study (MSA) Excel Template
[9] Dimensional Results:
→ A list of every dimension noted on the ballooned drawing.
→ This list shows the product characteristic, specification, the measurement results, and the assessment showing if this dimension is “ok” or “not ok”.
[10] Records of Material / Performance Test Results:
→ A summary of every test performed on the part.
→ This summary is usually on a form of DVP&R (Design Verification Plan and Report), which lists each individual test when it was performed, the specification, results, and the assessment pass/fail.
→ The DVP&R shall be reviewed and signed off by both customers and suppliers.
→ In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print.
[11] Initial Process Studies:
→ Usually, this section shows all
Statistical Process Control (SPC) Charts affecting the most critical characteristics.
→ The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value.
→ It is also known as the Process Capability Study.
[12] Qualified Laboratory Documentation:
→ Copy of all laboratory certifications of the laboratories that performed the tests reported.
→ Also required all calibration certificates of all Measuring instruments and Testing Equipment
[13] Appearance Approval Report (AAR):
→ A copy of the AAR (Appearance Approval Report) form signed by the customer.
→ Applicable for components affecting appearance only and required by the customer.
👉 Download Appearance Approval Report Excel Template
[14] Sample Production Parts:
→ A sample from the same lot of initial production run.
→ The PPAP package usually shows a picture of the sample and where it is kept.
[15] Master Sample:
→ 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:
→ When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including a dimensional report of the tool.
[17] Customer-Specific Requirements:
→ Each customer may have specific requirements to be included in the PPAP.
→ In general, it should be the length, width, height, weight, GSM, or any technical value depends on the product.
[18] Part Submission Warrant (PSW):
→ 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.
👉 Download Part Submission Warrant Excel Template
PPAP Approval Status:
[A] Approved:
⇢ The part meets all the customer's requirements.
⇢ The supplier is authorized to ship production quantities of the part.
[B] Interim Approved:
⇢ Permits shipment of the part on a limited time or piece quantity basis.
[C] Rejected:
⇢ The part does not meet the customer's requirements.
FAQs
How long does it take for TI to provide a PPAP after submitting a request? You can expect to receive level 1 PPAP documentation within the same day and requests for higher levels in 10 to 15 days, depending on the specific request.
How many PPAP documents do I need? ›
There are 18 required documents which are referred to as PPAP elements.
What is the main purpose of production part approval process PPAP? ›
The purpose of the PPAP is to ensure that the customer's design has been understood by the supplier and to prove that the supplier is capable of producing parts that meet all the requirements consistently.
What is a PPAP sample? ›
PPAP (pronounced P-PAP) is a design & manufacturing inspection process used to verify a supplier's ability to reliably and repeatedly produce a part or set of parts for mass production. PPAP validates a production process by inspecting parts before, during, and after a production run.
What is master sample in PPAP? ›
The PPAP package usually shows a picture of the sample and where it is kept (customer or supplier). Master Sample. A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections such as visual or for noise.
What is required for a Level 3 PPAP? ›
A Level 3 PPAP requires that you submit all the documentation of a PPAP except elements 15 and 16, which are the master sample and checking aids. InspectionXpert needs the contact information you provide to us to contact you about our products and services.
What is required for a Level 2 PPAP? ›
A level 2 PPAP would need to include design records of saleable products as well as all other components and details. You would also need to include dimensional results, materials and performance test results, as well as qualified laboratory documentation.
Is PPAP mandatory? ›
A PPAP is required for each product line family intended to be supplied for automotive use. Each company and industry has their own product specific definition of a product line family.
Is PPAP a legal requirement? ›
Currently, the only parts requiring PPAP approval are those used by the automotive industry. The Automotive Industry Action Group (AIAG) mandates PPAP approval for the automotive industry.
Who is responsible for PPAP? ›
Suppliers, not customers, are responsible for PPAPs. For a supplier, this means maintaining a quality system that documents all of the requirements of a PPAP submission is a necessity.
Process Flow Diagram, also known as a process flow chart, shows the document and clarifies all steps required in the manufacturing of the part in question. The process flow diagram must match both the control plan and the Process Failure Mode and Effects Analysis (PFEMA).
When should PPAP be used? ›
When is a PPAP required? A Production Part Approval Process (PPAP) is required anytime a new part of change to an existing part or process is being planned. A customer may request a PPAP at any time during the life of a product.
What is PPAP documents PDF? ›
The PPAP Documents List. Design Records. A copy of the drawing. If the customer is responsible for designing, this is a copy of the customer drawing that is sent together with the Purchase Order (PO). If the supplier is responsible for designing this is a released drawing in the supplier's release system.
What is the difference between APQP and PPAP? ›
APQP is a process that happens during the product development lifecycle to facilitate transparent communication and feedback throughout the supply chain. This process allows suppliers to detect errors early on, incorporate customer feedback, and deliver high quality products. PPAP is an output of APQP.
How many phases are there in PPAP process? ›
There are five phases to APQP; PPAP is triggered in Phase 4, Product & Process Validation. On the surface, PPAP can appear to be complicated and even overwhelming.
What is PPAP in quality PPT? ›
Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP)
Is Imds part of PPAP? ›
IMDS aids the customer in the supply network to verify the contents of their purchased parts before and during the part approval process. The Production Part Approval Process (PPAP) requires IMDS submission for each part number before PPAP approval can be granted to the supplier.
What is off tool and off process? ›
Off Tool: (Production Tooling) - When a part is said to be “Off Tool” it is required that the part be manufactured using the exact tooling which will be used for long-term production. This does NOT mean the parts were manufactured from tooling that is “like” or “similar” to the intended production tooling.
What is control plan in quality? ›
A control plan is a living document that outlines the methods taken for quality control of critical inputs to deliver outputs that meet customer requirements. It also provides a written description of the measurements, inspections, and checks put in place to control production parts and processes.
What is the general default level for PPAP submission? ›
The level to be submitted is determined by the WBT site, and unless otherwise noted' always defaults to Level 3 which is a full PPAP submission.
What is an APQP Checklist? APQP checklists are tools used by CFTs to achieve optimum results throughout the APQP process—pre-planning, designing, developing, and validating the product and the process, launching the product, and assessing it for continuous improvement.
What are 4 types of quality control? ›
What are the four types of Quality Control? The four types of quality control are process control, control charts, acceptance sampling, and product quality control.
Which are the 7 QC tools? ›
What are the 7 basic quality tools?
- Stratification.
- Histogram.
- Check sheet (tally sheet)
- Cause and effect diagram (fishbone or Ishikawa diagram)
- Pareto chart (80-20 rule)
- Scatter diagram.
- Control chart (Shewhart chart)
It is the technique par excellence of quality tools. They are the abbreviations of Failure mode and effects analysis (FMEA). FMEA is based on the application of a procedure for classifying potential failures based on their severity, frequency and detection capacity.
What is dimensional result in PPAP? ›
The Dimensional Results Report (DRR) provides a record of the dimensional data taken from product produced during the production process run. Unless the customer specific requirements (PPAP Element 18) differ, the results relate to the method defined within the Test Inspection Criteria (TIC) for ongoing production.
What is the latest Apqp edition? ›
Advanced Product Quality Planning & Control Planning (APQP), 2nd Edition.
What is a PPAP waiver? ›
There are two types of waivers: Waiver of PPAP just for the first shipment. This allows an order to be processed and the first shipment to be sent out, even though the PPAP Approval process is not yet completed. Waiver that attests that no PPAP is needed.
How many types of PPAP are there? ›
Level 1: Only the Part Submission Warrant (PSW). Level 2: PSW with product samples and limited supporting data. Level 3: PSW with product samples and complete supporting data. Level 4: PSW and other requirements as defined by the customer.
What are the 3 types of process flow diagram? ›
In 1987, Andrew Veronis published a book called Microprocessors: Design and Application that described the following three types of flowcharts: System flowchart. General flowchart. Detailed flowchart.
What is AIAG standard? ›
The Automotive Industry Action Group (AIAG) was established in 1982, AIAG is a not-for-profit trade association where professionals from member companies – including automakers, suppliers of all sizes, manufacturers, service providers, academia, and government – work collaboratively to streamline industry processes via ...
ADVANCED PRODUCT QUALITY PLANNING (APQP) AND PRODUCTION. PART APPROVAL PROCESS (PPAP)
Is PPAP a legal requirement? ›
Currently, the only parts requiring PPAP approval are those used by the automotive industry. The Automotive Industry Action Group (AIAG) mandates PPAP approval for the automotive industry.
Who is responsible for PPAP? ›
Suppliers, not customers, are responsible for PPAPs. For a supplier, this means maintaining a quality system that documents all of the requirements of a PPAP submission is a necessity.
Is PPAP mandatory? ›
A PPAP is required for each product line family intended to be supplied for automotive use. Each company and industry has their own product specific definition of a product line family.
What are the 18 documents of PPAP? ›
There are 18 documents that comprise the PPAP:
- Design Records. ...
- Engineering Change Documentations, if any.
- Customer Engineering approval, if required.
- Design Failure Mode and Effect Analysis (DFMEA)
- Process Flow Diagrams.
- Process Failure Mode and Effect Analysis (PFMEA)
- Measurement System Analysis Studies.
- Dimensional Results.
APQP is a process that happens during the product development lifecycle to facilitate transparent communication and feedback throughout the supply chain. This process allows suppliers to detect errors early on, incorporate customer feedback, and deliver high quality products. PPAP is an output of APQP.
What is required in a Level 3 PPAP? ›
A Level 3 PPAP requires that you submit all the documentation of a PPAP except elements 15 and 16, which are the master sample and checking aids. InspectionXpert needs the contact information you provide to us to contact you about our products and services.
Is Imds part of PPAP? ›
IMDS aids the customer in the supply network to verify the contents of their purchased parts before and during the part approval process. The Production Part Approval Process (PPAP) requires IMDS submission for each part number before PPAP approval can be granted to the supplier.
What are the 5 levels of PPAP? ›
What are the five levels of PPAP?
- Level 1 – Part Submission Warrant (PSW) only.
- Level 2 – PSW with product samples and limited supporting data.
- Level 3 – PSW with product samples and complete supporting data.
- Level 4 – PSW and other requirements as defined by the customer.
Level 1: Only the Part Submission Warrant (PSW). Level 2: PSW with product samples and limited supporting data. Level 3: PSW with product samples and complete supporting data. Level 4: PSW and other requirements as defined by the customer.
There are two types of waivers: Waiver of PPAP just for the first shipment. This allows an order to be processed and the first shipment to be sent out, even though the PPAP Approval process is not yet completed. Waiver that attests that no PPAP is needed.
What is PPAP in quality PPT? ›
Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP)
How many phases are there in PPAP process? ›
There are five phases to APQP; PPAP is triggered in Phase 4, Product & Process Validation. On the surface, PPAP can appear to be complicated and even overwhelming.
What is process flow diagram in PPAP? ›
Process Flow Diagram, also known as a process flow chart, shows the document and clarifies all steps required in the manufacturing of the part in question. The process flow diagram must match both the control plan and the Process Failure Mode and Effects Analysis (PFEMA).
When should PPAP be used? ›
When is a PPAP required? A Production Part Approval Process (PPAP) is required anytime a new part of change to an existing part or process is being planned. A customer may request a PPAP at any time during the life of a product.
What is PPAP in quality PDF? ›
Production Part Approval Process (PPAP) Assessment.
