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 product approval, apart from approving the production process and validating the manufactured product, supervised by the engineering department. The main goals of PPAP are:
- Defining actions and responsibilities to ensure the correct application of the part approval process in the pre-launch phase and current production
- Verifying that all customer requirements have been fully understood by the supplier
- Checking that the off-Tool off Process (OTOP) will enable the production of parts compliant with these requirements
- Verifying the passage of tests carried out for confirmation within the prescribed time
- Ensuring the final production process in the final location (OTOP) retains all functional, reliability, dimensional, and aesthetic characteristics
We sometimes say that PPAP summarizes our work as a supplier and culminates in Advanced Product Quality Planning (APQP).
From the IATF point of view, the requirement that includes PPAP we can find in section 8.3.4.4 – Product Approval Process. An important aspect mentioned in this section is the need to complete the approval process of externally supplied components (often referred to as “buy components”) before submitting the final product.
It is recommended that part submission should occur after internal or external verification of the manufacturing process by a customer representative (e.g., SQE, STA).
PPAP Elements
During PPAP, the organization must submit 18 elements to the customer to guarantee that the supplier can meet the appropriate quality and quantity requirements for the manufactured product. These elements are:
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 required submission level (from 1 to 5), there are two approaches:
- Submit to the client and keep copies of documents and samples in an appropriate place.
- Keep 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 customerβthe default level is level 3. The customer must approve it 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, i.e., 1 to 8 hours, and a minimum of 300 consecutive parts, unless otherwise agreed in writing with the customer. Additionally, the production process should be in OTOP (off-tool off-process) status, meaning it should be final and located in a definitive production location.
It is also important to remember that when submitting parts dedicated to PPAP to the client, approval should be obtained for all sub-components included in the manufactured product.
Product Approval Process β What mistakes to avoid?
The Production Part Approval Process (PPAP) is vital for organizations during both new product launches and ongoing production. Understanding common pitfalls is essential to meet compliance requirements within the required timeframe.
If you want to know how to navigate PPAP efficiently and avoid mistakes to ensure timely approvals, you’re in luck! You’ll find this information in a separate article on our blog page.
And what about PPAP samples preparation? We also describe this activity on our blog page.
What are the part submission levels for PPAP?
There are five PPAP levels. They are associated with the scope of documentation required. If the customer does not specify which level to use, then by default Level 3 applies. This is the most demanding level, where you essentially need to complete all 18 documents referenced in the AIAG PPAP manual.
Of course, it may happen that some documents do not apply to us. For instance, if there are visual characteristics that do not relate to our product. The remaining levels are:
Level 1
In this case, we only submit the PSW (Part Submission Warrant). This is the βlightestβ type of PPAP, typically used when the customer trusts usβsuch as when we have a long-standing cooperation, no quality issues and the change is not so significant as to require additional evidence that the product will remain compliant. It requires the least effort from suppliers.
Level 2
At Level 2, we also submit the PSW, five samples and a selected set of documentation chosen by the customer. This might include, for example, only dimensional measurement results for those samples.
Level 3
This is the most complex level. You must submit all the required documents.
Level 4
At Level 4, you submit the PSW and only the documents requested by the customer. There is no mention of samples in this level.
Level 5
At Level 5, you provide the PSW, samples and the documentation package selected by the customer. However, the full documentation remains available for review at the supplierβs location. This level is most often conducted in conjunction with a process audit.
Frequently Asked Questions (FAQ) About PPAP
Q1: What is the main purpose of PPAP?
A1: To confirm that the supplier can consistently meet all customer specifications before full production.
Q2: How many PPAP levels are there?
A2: There are five submission levels, ranging from Level 1 (lightest) to Level 5 (most comprehensive).
Q3: What is OTOP in PPAP?
A3: Off-Tool Off-Process β the final production state used for submitting representative samples.
Q4: Who approves a PPAP submission?
A4: Typically, the customerβs quality or supplier development engineers.
Q5: When is a PPAP required?
A5: When launching new parts, making major changes, or after corrective actions.
Q6: What happens if PPAP is not approved?
A6: The supplier cannot proceed with mass production until full compliance is achieved.
Conclusion
The PPAP β Production Part Approval Process is an indispensable quality assurance tool in manufacturing. By understanding its requirements, documenting thoroughly, and avoiding common mistakes, suppliers can ensure fast approvals, satisfied customers, and robust production readiness.
Author: Dariusz Kowalczyk
