PPAP: Production Part Approval Process

PPAP – Production Part Approval Process

A Pillar of Quality Assurance in Automotive & Manufacturing Industries

In the automotive and manufacturing industry, ensuring consistent product quality is not optional—it is mandatory. Customers expect every supplied part to meet specifications from the first piece through the millionth piece without variation. To achieve this level of consistency and reliability, suppliers must demonstrate that their production process, measurement system, and quality controls are capable, stable, and repeatable.

This verification process is known as PPAP – Production Part Approval Process.

PPAP is a structured methodology developed by AIAG (Automotive Industry Action Group) that validates whether a supplier understands all customer requirements and confirms that the production process can deliver products consistently during real production conditions. It is a key component of the 5 Core Tools (APQP, PPAP, FMEA, MSA, SPC) and an essential requirement for compliance with IATF 16949 automotive standards.

What Is PPAP?

PPAP (Production Part Approval Process) is a documented approval procedure that ensures a supplier can produce parts meeting all engineering specifications, quality standards, and customer expectations during actual production.

It provides objective evidence that:

  • The product design is understood
  • The production process is capable and stable
  • The measurement systems are accurate and reliable
  • All potential risks have been analyzed and controlled
  • The part delivered will consistently meet quality expectations

In simple words:

PPAP builds confidence that the product will be right the first time and every time after.

Why PPAP Is Important

Even if the design is perfect, a product fails in the market if the manufacturing process cannot consistently deliver good parts. PPAP prevents this risk by confirming readiness before full-scale production begins.

Key benefits of PPAP

✔ Consistent quality across batches and time
✔ Reduction in defects, scrap, rework, and warranty claims
✔ Establishes strong communication between customer & supplier
✔ Validates process capability and controls
✔ Ensures traceability and documentation discipline
✔ Provides confidence for safe production startup
✔ Supports continuous improvement

PPAP is not just paperwork or form submission—it is a quality assurance checkpoint that verifies the process, not just the part.



When Is PPAP Required?

PPAP is typically required in situations such as:

  • New product or part introduction
  • Engineering design or material change
  • Change in manufacturing process or location
  • New tooling, replacement tooling, or tooling refurbishment
  • Change in supplier or subcontractor
  • Significant quality concern or customer complaint
  • After long-duration production shutdown

PPAP ensures that any change does not introduce unknown risks or deviations in quality.

Levels of PPAP Submission

AIAG defines five levels of PPAP submission based on customer requirements:

Level

Details

Level 1

Part Submission Warrant (PSW) only

Level 2

PSW + limited supporting data

Level 3 (Most Common)

PSW + complete documentation package

Level 4

PSW + customer-specific requirements

Level 5

PSW + complete documentation and full package for on-site audit

Most customers, especially automotive OEMs and Tier-1 suppliers, require Level 3 PPAP for standard submissions.

 

The 18 Elements of PPAP

A Level 3 PPAP package includes the following 18 documents:

  1. Design Records
  2. Authorized Engineering Change Documents
  3. Engineering Approval
  4. Design FMEA
  5. Process Flow Diagram (PFD)
  6. Process FMEA (PFMEA)
  7. Control Plan
  8. Measurement System Analysis (MSA)
  9. Dimensional Results
  10. Material / Performance Test Results
  11. Initial Process Studies (Cp/Cpk)
  12. Qualified Laboratory Documentation
  13. Appearance Approval Report (AAR)
  14. Sample Product
  15. Master Sample
  16. Checking Aids / Gauges
  17. Customer Specific Requirements
  18. Part Submission Warrant (PSW)

These elements together confirm that:

  • The design requirements are understood
  • The process flow and controls are strong
  • Measurement systems are capable
  • Process variation is under control
  • Parts produced meet all dimensional and material requirements

Purpose and Objectives of PPAP

PPAP ensures that:

📌 The production process is capable (acceptable Cp/Cpk values)
📌 Potential failure modes are identified and actions taken through PFMEA
📌 Measurement systems are accurate (MSA approval)
📌 Material used meets specification and safety standards
📌 Sample parts meet drawing and dimensional requirements
📌 The supplier is ready for SOP (Start of Production)

PPAP serves as a proof of preparedness, allowing the customer to approve the part for full-scale manufacturing.

 

Real-World Example

A supplier manufactures automotive shafts with a critical diameter requirement of Ø16.000 ± 0.005 mm. Even if the machining process is capable, rejecting or accepting parts incorrectly can occur if the measurement system is unreliable.

During PPAP, the customer reviews:

  • Dimensional results report from sample parts
  • Machine capability study showing Cp & Cpk > 1.67
  • MSA study confirming Gauge R&R < 10%
  • Control Plan demonstrating process monitoring
  • PFMEA identifying risks and actions

Once confirmed, the customer approves PPAP and authorizes production.

If any document fails, PPAP prevents future defects and warranty claims.

Benefits of PPAP

A strong PPAP system results in:

For Customers

⭐ Fewer quality issues and complaints
⭐ Reduced warranty and recall risks
⭐ Higher supplier reliability & trust
⭐ Stable production performance

For Suppliers

⭐ Reduced rework, scrap, and inspection cost
⭐ Better understanding of the customer system
⭐ Improved internal controls and documentation
⭐ Stronger reputation and business opportunities

Ultimately:

PPAP enables defect prevention rather than defect detection.

Conclusion

PPAP is an essential core tool in manufacturing and automotive industries to verify readiness before launching full production. It confirms that the supplier understands requirements, the process is capable, and any risks are controlled. A properly executed PPAP prevents startup failures, customer complaints, and costly rework, helping both supplier and customer achieve reliable, consistent, zero-defect production.

In a competitive industry where customer satisfaction and product quality determine success,

PPAP ensures:

✔ The right part
✔ At the right quality
✔ In the right quantity
✔ Delivered consistently every time

When APQP builds the quality foundation,
PPAP validates that the foundation is strong for real production.


#PPAP #ProductionPartApprovalProcess #AIAG #AutomotiveQuality #ManufacturingQuality #SupplierQuality #QualityManagement #CoreTools #APQP #FMEA #ControlPlan #MSA #SPC #ProcessValidation #QualityAssurance #QualityEngineer #ManufacturingExcellence #LeanManufacturing #ContinuousImprovement #ProcessCapability






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