PPAP

Production Part
Approval Process

By: Subhransu Mohanty

 History of PPAP
• The Production Part Approval Process (PPAP) originated in the 1980s as part of
the efforts by the Automotive Industry Action Group (AIAG) to standardize quality
practices in the automotive supply chain. With the increasing complexity of
automotive components and globalization of supply chains, automotive
manufacturers sought a consistent method to ensure suppliers could meet design
and production requirements.

• Initially introduced by the Big Three U.S. automakers—Ford, General Motors, and
Chrysler—PPAP became a foundational quality framework. Over time, its adoption
spread to other manufacturing sectors, such as aerospace, electronics, and heavy
machinery, as organizations recognized the value of validating suppliers'
production processes.

By: Subhransu Mohanty

 Key Objectives of PPAP
• Validation: Verify that the supplier’s production
process can meet customer requirements.

• Consistency: Ensure parts are produced consistently

at acceptable quality levels.

• Risk Reduction: Minimize risks associated with

defective components by analyzing processes and
controls upfront.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
The PPAP submission package includes 18 key elements, though not all are mandatory for
every project. Customers specify which documents they require based on their needs.

1. Design Records
A design record is a customer-approved drawing or specification that outlines the
part's features, dimensions, materials, and tolerances. It may include CAD files
and their revision history.
• Example: For an automotive bracket, the design record might include a CAD drawing
showing the exact dimensions, material type (e.g., aluminum alloy), and surface finish
requirements.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
2. Engineering Change Documents
These documents detail approved changes to the part design or production
process, ensuring traceability and compliance.
• Example: If a change is made to use a stronger material for a car’s suspension
spring, the supplier must submit an engineering change notice and the customer's
approval of the updated specifications.
3. Engineering Approval
Engineering approval involves the customer's verification and acceptance of
prototype parts or initial production samples.
• Example: A customer might conduct performance tests on a prototype fuel injector
and issue a signed approval document confirming it meets design expectations.
By: Subhransu Mohanty
 Documents Required for
PPAP Submission
4. Design Failure Mode and Effects Analysis (DFMEA)
DFMEA identifies potential design failures, their causes, and the impact on the
product, along with strategies to mitigate risks.
• Example: For an electric motor, a DFMEA might highlight a potential risk of
overheating due to insufficient ventilation and propose increasing vent size as a
mitigation strategy.
5. Process Flow Diagram (PFD)
A PFD visually maps the entire production process, from raw materials to
finished goods, to ensure each step is defined and controlled.
• Example: For a tire production process, the PFD might include steps like material
mixing, molding, curing, inspection, and packaging.
By: Subhransu Mohanty
 Documents Required for
PPAP Submission
6. Process Failure Mode and Effects Analysis (PFMEA)
PFMEA examines process risks, causes of defects, and preventive measures for
each production step.
• Example: In a stamping process, PFMEA might identify the risk of burr formation on
edges and recommend periodic tool sharpening to minimize defects.
7. Control Plan
The control plan outlines methods for monitoring and controlling the production
process to maintain consistent quality.
• Example: For a car door assembly line, the control plan might specify inspection
intervals for bolt torque, paint thickness, and alignment accuracy.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
8. Measurement System Analysis (MSA)
MSA validates the accuracy and reliability of measurement tools using studies
like Gauge Repeatability and Reproducibility (Gauge R&R).
• Example: Before using a caliper to measure part thickness, a Gauge R&R study
ensures that the tool gives consistent readings across operators.
9. Dimensional Results
This report includes measurements of production parts to confirm they meet
design specifications.
• Example: For a gear, the dimensional results might show measured values for
diameter, tooth height, and pitch compared to the required tolerances.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
10. Records of Material/Performance Tests
These records demonstrate compliance with material and performance standards
through laboratory testing.
• Example: Testing might confirm that a plastic housing for an electronic device meets
flammability resistance standards like UL 94.
11. Initial Process Studies
Statistical studies such as Cpk and Ppk are used to evaluate process capability and
ensure parts consistently meet specifications.
• Example: A stamping process might have a Cpk of 1.5 for part thickness, indicating
the process is highly capable.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
12. Qualified Laboratory Documentation
Documentation includes certifications from accredited labs for conducting tests.
• Example: An ISO 17025-certified lab might provide a tensile strength test report for a
steel component.
13. Appearance Approval Report (AAR)
The AAR ensures the part's aesthetics, such as color, texture, and finish, meet
customer expectations.
• Example: A dashboard trim must match the approved matte black color and surface
texture specified by the customer.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
14. Sample Product Parts
These are physical parts submitted to the customer to represent production-ready
components.
• Example: For a brake pad, a supplier might submit 5 production samples for
customer testing and evaluation.
15. Master Sample
The master sample is a customer-approved reference part used for comparison
during ongoing production.
• Example: A stamped metal washer approved as the master sample is used to verify
dimensional accuracy in future production runs.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
16. Checking Aids
Documentation of inspection tools or gauges used for verifying part quality and
compliance.
• Example: A custom gauge for measuring the inner diameter of a cylinder is listed in the
PPAP submission.
17. Customer-Specific Requirements
Any additional requirements or documentation mandated by the customer, beyond
standard PPAP elements.
• Example: A customer might require a separate sustainability report detailing the
environmental impact of the production process.

By: Subhransu Mohanty

 Documents Required for
PPAP Submission
18. Part Submission Warrant (PSW)
The PSW is a formal declaration from the supplier that the part meets all customer
specifications and PPAP requirements.
• Example: A PSW for a car’s headlight assembly certifies compliance with dimensional,
material, and performance standards.

By: Subhransu Mohanty

 What is
Part Submission Warrant (PSW)
The Part Submission Warrant (PSW) is a critical document within the Production Part
Approval Process (PPAP). It serves as the supplier's formal declaration that a part or
product meets all customer specifications and requirements.
Purpose of PSW
• Compliance Assurance: Confirms that the supplied part adheres to all design records,
specifications, and agreed-upon requirements.
• Customer Communication: Acts as the official submission from the supplier to the
customer, certifying readiness for production.
• Quality Guarantee: Demonstrates that the supplier has validated the production process
to deliver consistent, high-quality parts.
By: Subhransu Mohanty
 What is
Part Submission Warrant (PSW)
Key Components of the PSW
Part Information Declaration of Compliance
•Part name and description.
•Confirms that all PPAP requirements have been met and are included in
•Part number as per the design record. the submission.
•Engineering change level and release date.

Supplier Information
Submission Level
•Supplier name and location.
•Specifies the PPAP submission level (1–5).
•Supplier code or identification number.
Dimensional and Material Compliance
Customer Information
•Evidence that dimensions, material, and performance tests meet customer
•Customer organization details. specifications.
•Program or project name (if applicable).
Authorized Signature
Reason for Submission
•Signed by a responsible supplier representative to confirm the accuracy
•Explains why the PSW is being submitted, such as: and authenticity of the submission.
•New part introduction.
•Engineering design change.
•Process change (e.g., tooling or material).
•Supplier location change.
•Correction of discrepancies found in prior submissions.

By: Subhransu Mohanty

 What is
Part Submission Warrant (PSW)

When is a PSW Used? Example Scenario of a PSW Submission

A PSW is typically submitted during: A supplier produces brake pads for a

vehicle manufacturer:
• New Part Approval: For first-time production parts. • After completing the PPAP, including dimensional
• Design Changes: When there are modifications to reports, material tests, and process validation, the
the part or process. supplier prepares a PSW.
• Tooling or Material Changes: For significant • The PSW declares compliance with design
specifications, supported by attached test results and
changes that might impact the part’s quality. engineering approvals.
• Location Changes: When production moves to a • The supplier submits the PSW to the customer for final
new manufacturing site. approval.
• Upon approval, the customer authorizes mass
production.

By: Subhransu Mohanty

 What is
Part Submission Warrant (PSW)
Key Tips for Preparing a PSW
1. Ensure Completeness: Verify all required PPAP documents are included in the submission.
2. Double-Check Accuracy: Validate that part numbers, specifications, and test results match
customer requirements.
3. Involve Cross-Functional Teams: Collaborate with quality, design, and production teams for
accuracy.
4. Communicate with the Customer: Clarify expectations for submission levels and
documentation.
5. Maintain Traceability: Keep a record of all related documents and approvals for future
reference.

By: Subhransu Mohanty

 PPAP Submission Levels

There are five levels of PPAP submission, ranging from minimal

documentation to a full package with parts:
• Level 1: PSW only.
• Level 2: PSW with limited supporting data.
• Level 3: Full PPAP submission (most common).
• Level 4: PSW with specific customer-defined requirements.
• Level 5: Full PPAP with on-site verification by the customer.

By: Subhransu Mohanty

 PPAP Submission Levels

Level 1: Part Submission Warrant (PSW) Only

This is the simplest form of PPAP submission, requiring minimal documentation. It’s
typically used for low-risk components or when the customer already has substantial
confidence in the supplier’s process.
Requirements
1. Part Submission Warrant (PSW): Declaration that the part meets customer requirements.
2. Additional Customer-Specified Documents (if requested): E.g., drawings or limited test reports.

By: Subhransu Mohanty

 PPAP Submission Levels
Level 2: PSW with Limited Supporting Data
This level involves slightly more documentation, suitable for non-critical parts with
fewer risks.
Requirements
1. PSW
2. Design Records: Approved drawings or specifications.
3. Dimensional Results: Limited measurement data for key dimensions.
4. Material Test Results: Evidence of compliance with material specifications.
5. Performance Test Results: Verification of critical performance characteristics.

By: Subhransu Mohanty

 PPAP Submission Levels
Level 3: Full PPAP Submission (Most Common)
The most comprehensive level, used for critical or new parts, requiring submission of all
documents and records to verify part quality.
Requirements
1. PSW
2. Design Records
3. Engineering Change Documents (if applicable)
4. Engineering Approval (for prototypes or pre-launch parts)
5. DFMEA: Identification and mitigation of design risks.
6. Process Flow Diagram (PFD): End-to-end production workflow.
7. PFMEA: Identification of process risks and preventive actions.

By: Subhransu Mohanty

 PPAP Submission Levels
8. Control Plan: Quality control measures for each production step.
9. MSA: Validation of measurement tools (e.g., Gauge R&R studies).
10. Dimensional Results: Comprehensive report on all key dimensions.
11. Material and Performance Test Results: Laboratory test data for material and performance
compliance.
12. Initial Process Studies: Capability studies (e.g., Cpk) for critical processes.
13. Qualified Laboratory Documentation: Certifications from testing labs.
14. Appearance Approval Report (AAR) (if applicable): Aesthetic compliance (e.g., color, texture).
15. Sample Product Parts: Physical samples for customer inspection..

By: Subhransu Mohanty

 PPAP Submission Levels
16. Master Sample: Customer-approved reference part.
17. Checking Aids: Documentation of tools used to inspect or measure parts.
18. Customer-Specific Requirements: Any additional customer-mandated
requirements

By: Subhransu Mohanty

 PPAP Submission Levels
Level 4: PSW and Customer-Specified Requirements Only
This level is customized based on customer-defined requirements. It is often
used for unique projects or low-volume parts.
Requirements
• PSW
• Selective Supporting Documents: Determined by the customer.
• Example: Control Plan, Process Flow Diagram, or key inspection data.

By: Subhransu Mohanty

 PPAP Submission Levels
Level 5: Full PPAP with On-Site Review
The most detailed level, requiring the supplier to submit all documents and
facilitate an on-site audit by the customer. This is used for complex, safety-
critical, or high-risk parts.
Requirements
1. All Level 3 Documents: Full PPAP package submission.
2. On-Site Process Review:
o Customer audits production processes, equipment, and quality controls.
o Verification of documentation and adherence to approved processes.
3. Live Demonstrations (if required): Real-time testing or production runs to confirm
capability.
By: Subhransu Mohanty
 PPAP Submission Levels
Stage-Wise PPAP Requirements
PPAP is typically broken into stages corresponding to Stage 3: Production Validation
the production lifecycle: • Documents: Complete PPAP package.
Stage 1: Pre-Production/Prototype
• Activities: Submission of all required
• Documents: Design Records, Engineering Approval,
documentation, process audits, and customer
Preliminary DFMEA.
approval.
• Activities: Prototype builds, testing, and initial
• Focus: Final validation before mass production.
feedback.
Stage 4: Mass Production
• Focus: Validation of the design feasibility.
• Documents: Ongoing compliance with PPAP
Stage 2: Pilot/Initial Production documents and periodic revalidations.
• Documents: Full DFMEA, PFMEA, Process Flow
• Activities: Routine inspections and audits to
Diagram, Initial Process Studies, Control Plan.
maintain quality standards.
• Activities: Trial runs to verify processes and controls.
• Focus: Sustaining consistent quality in mass
• Focus: Process capability and consistency. production.
By: Subhransu Mohanty
 PPAP Submission Levels
Example Scenario: Manufacturing an Automotive Brake Pad
1. Design Records: Supplier submits CAD drawings approved by the customer for the
brake pad.
2. DFMEA and PFMEA: Identify risks such as uneven wear or manufacturing defects and
address them with robust designs and processes.
3. Control Plan: Specifies control methods, such as checking pad thickness every 50
pieces.
4. MSA and Capability Studies: Validate measurement tools and ensure Cpk > 1.33 for
critical dimensions.
5. Sample Product: Deliver initial brake pad samples for customer approval.
6. PSW: Declare readiness for mass production.
By: Subhransu Mohanty
 Key Tips for Successful
PPAP Submission
1. Understand Customer Requirements: Clarify expectations early to avoid rework.
2. Ensure Cross-Functional Team Involvement: Include design, quality, and
manufacturing teams to address all aspects of PPAP.
3. Prepare Early: Begin collecting and verifying required data as soon as possible.
4. Focus on Robust PFMEA: A thorough PFMEA helps address potential process risks.
5. Validate Measurement Systems: Ensure accuracy and repeatability of gauges and
tools before dimensional inspections.
6. Communicate Clearly: Maintain open communication with the customer throughout
the submission process.
7. Use Checklists: Leverage AIAG PPAP manuals and checklists to ensure no documents
are missed.
By: Subhransu Mohanty
 Conclusion
PPAP is a cornerstone of quality management in manufacturing, providing
confidence in the supplier’s capability to deliver consistent, high-quality
products. With proper planning, collaboration, and attention to detail,
successful PPAP submission can strengthen supplier-customer relationships
and ensure smooth production.

By: Subhransu Mohanty

Thank You !
By: Subhransu Mohanty