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:
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.
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
A production part sent to the customer for approval per their request
Sample of the product inspected and signed off by the customer used to train operators and a benchmark for ongoing production
Aids used by production to inspect, test or measure parts during the production process