Scenario
Your factory just received a Tier 1 automotive part order, and the customer requested "PPAP Level 3 submission." Your Quality Assurance manager assigned you the task, saying: "Go take care of PPAP."
You open the AIAG manual, see 18 elements, and don't know where to start.
What is PPAP
PPAP (Production Part Approval Process) = Production Part Approval Process
A standard established by AIAG (Automotive Industry Action Group), its purpose is to confirm that a supplier has the capability to consistently produce parts meeting specifications before mass production.
Core Question of PPAP: Does the supplier have the capability to consistently mass produce this part?
5 Submission Levels
| Level | Requirements | Applicable Scenarios |
|---|---|---|
| 1 | Submit PSW (Part Submission Warrant) only | Low-risk standard parts |
| 2 | PSW + limited supporting documentation and samples | Medium-low risk |
| 3 | PSW + full supporting documentation + samples | Most common, standard requirement for new parts |
| 4 | PSW + customer-specified documentation | Customer special requirements |
| 5 | Customer reviews all documentation at the supplier's manufacturing location | High-risk parts |
Overview of the 18 Elements
Core Documentation Category:
- Design Records: drawings, CAD models
- Engineering Change Documents: if design changes exist
- Customer Engineering Approval: when the design is provided by the customer
- DFMEA (Design Failure Mode and Effects Analysis): when design responsibility belongs to the supplier
- Process Flow Diagram
- PFMEA (Process Failure Mode and Effects Analysis)
- Control Plan
Process Validation Category:
- MSA Studies (Measurement System Analysis): Gage R&R for critical gages
- Dimensional Results: actual measured values for all drawing dimensions
- Material / Performance Test Results
- Initial Process Studies: Cpk ≥ 1.67 for critical CTQs
Laboratory and Appearance Category:
- Qualified Laboratory Documentation
- Appearance Approval Report (AAR): when aesthetic parts are involved
Sample Category:
- Sample Parts: typically 1-3 pieces
- Master Sample: customer-approved reference sample
- Checking Aids: measurement fixtures, dedicated gages
Final Sign-off Category:
- Customer-Specific Requirements
- Part Submission Warrant (PSW): signed off after all elements are completed
When Re-PPAP is Required
- New part (first mass production)
- Design change (any drawing alteration)
- Change in process or equipment
- Change in supplier (raw material supplier)
- Resumption of production after a shutdown (typically exceeding 1 year)
Golden Quote
"PPAP is not just a stack of documents; it's a complete demonstration by the supplier to the customer saying, 'I am ready.' Behind each element lies a process risk to be controlled; missing any element means that risk has not been assessed."