Production Part Approval Process (PPAP)
Production Part Approval Process is a standardized quality framework, originating in the automotive industry, that documents supplier readiness for production. PPAP requires suppliers to demonstrate their manufacturing process can consistently produce parts meeting specifications at quoted production rates. The comprehensive documentation package provides evidence of design understanding, process capability, and quality system readiness.
Examples
Automotive component PPAP: A tier-one supplier submitting a new bracket for PPAP provides: design records, engineering change documents, customer engineering approval, design FMEA, process flow diagram, process FMEA, control plan, measurement system analysis, dimensional results, material test results, initial process capability study, and a part submission warrant.
PPAP levels: A customer specifies PPAP Level 3, requiring full documentation submission and part samples for review. For a minor change, they might accept Level 1, where the supplier retains documentation and submits only the warrant and appearance approval.
PPAP for process change: When a supplier changes manufacturing equipment, they notify the customer and submit updated PPAP documentation demonstrating that the new process achieves equivalent capability.
Definition
PPAP was developed by the Automotive Industry Action Group (AIAG) as part of the APQP (Advanced Product Quality Planning) framework. While automotive in origin, PPAP principles apply broadly to manufacturing suppliers who must demonstrate production capability.
The PPAP package typically includes 18 elements covering everything from design documentation through process capability evidence. The specific elements required depend on the submission level specified by the customer, ranging from Level 1 (limited documentation) to Level 5 (full documentation available at supplier site).
PPAP timing occurs after design release but before production shipments begin. Suppliers cannot ship production parts without customer approval of the PPAP submission. Changes to product or process may trigger re-submission requirements.
Procurement often coordinates PPAP requirements and timelines, ensuring suppliers understand expectations and submissions are complete before production need dates. Engineering and quality review technical elements, but procurement manages the commercial relationship and schedule implications.
Frequently asked questions
What is PPAP in simple terms?
The Production Part Approval Process (PPAP) is a standardized quality framework, originating in the automotive industry, that documents supplier readiness for production. PPAP requires suppliers to demonstrate their manufacturing process can consistently produce parts meeting specifications at quoted production rates, through a documentation package showing design understanding, process capability, and quality system readiness.
What are PPAP submission levels?
PPAP submission levels range from Level 1, where the supplier retains documentation and submits only the warrant and appearance approval, to Level 5, with full documentation available for review at the supplier's site. The customer specifies the level: Level 3, full documentation submission with part samples, is a common requirement for new parts, while a minor change might only need Level 1.
What documents go into a PPAP package?
A PPAP package typically spans 18 elements, with the required subset depending on the submission level. For a new automotive bracket, that includes design records, engineering change documents, customer engineering approval, design FMEA, process flow diagram, process FMEA, control plan, measurement system analysis, dimensional results, material test results, an initial process capability study, and a part submission warrant.
When is PPAP required?
PPAP timing falls after design release and before production shipments begin; suppliers cannot ship production parts without customer approval of the submission. Changes to product or process can trigger re-submission, for example when a supplier changes manufacturing equipment and must demonstrate the new process achieves equivalent capability.
Who manages PPAP on the buyer side?
Procurement often coordinates PPAP requirements and timelines, making sure suppliers understand expectations and submissions are complete before production need dates. Engineering and quality review the technical elements, while procurement manages the commercial relationship and schedule implications. Though automotive in origin under AIAG's APQP framework, PPAP principles apply broadly to manufacturing suppliers who must demonstrate production capability.