PPAP ELEMENTS

The PPAP package is a series of documents that need a formal sign-off by suppliers and approval of the customer. The form that summarizes this package is called ‘Part Submission Warrant’ (PSW). The additional documents required in the PPAP package are used to show that all requirements are understood - risk reduction activities, process capability, products are right, and controls are in place to prevent non-conforming product reaching the customer. Suppliers are required to obtain PPAP approval from the vehicle OEMs whenever a new or modified component is introduced to production, or there is a change in the manufacturing process. Obtaining approval requires the supplier to provide sample parts and documentary evidence.

The PPAP submission requirements are normally divided into five levels of submission, depending on your customer’s requirements. The levels of submission correspond only to the amount and type of documents required in the package. The submission levels are as follows:

• Level 1 – Part Submission Warrant (PSW) only submitted to the customer
• 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 5 – PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location

Below is a chart illustrating the list of all 18 elements that are required for each of the 5 levels, I have also included a very brief description for each element:

Design Record

Any documents that demonstrate meeting customer specified characteristics such as dimensional, functional, critical, safety or appearance

Engineering Change Documents

Copies of any Engineering Change Notice (ECN) approved by the customer engineering

Customer Engineering Approval

Evidence illustrating the supplier obtained PPAP approval from customer engineering

Design FMEA (DFMEA)

Documented activity identifying possible failure modes and their effects on the product or assembly

Process Flow Diagram (PFD)

A graphical outline of the manufacturing process flow from incoming raw material to shipping

Process FMEA (PFMEA)

Documented review the operational process steps to identify potential risks and the applied prevention and detection controls

Process Control Plan (PCP)

Document listing all inspection methods and tools required to manufacture products per the customer requirements

Measurement System Analysis Studies (MSA)

Studies performed for measurement equipment including Gage Repeatability & Reproducibility (GR&R) and the calibration records

Dimensional Results or First Article Inspection Report (FAIR)

Dimensional layout of parts from the production run used to validate the product meets the print specifications.

Test Results

The Design Verification Plan and Report (DVP&R) is a summary of all validation tests performed on the part and their results.

Initial Process Studies

Evidence of the initial production run that demonstrates capability through validation and Statistical Process Control (SPC) charts for critical characteristics.

Qualified Laboratory Documentation

Documented industry certifications for any lab that was involved in completing validation testing.

Appearance Approval Report

Applicable for components appearance requirements only

Sample Products

A production part sent to the customer for approval per their request

Master Sample

Sample of the product inspected and signed off by the customer used to train operators and a benchmark for ongoing production

Checking Aids

Aids used by production to inspect, test or measure parts during the production process