10/26/21, 10:34 AM PPAP 101: What You Need to Know

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PPAP 101: What You Need to Know

QLM

Updated 8/18/2021

International quality standards for manufacturing continue to increase and many

industrial companies are requiring that their suppliers use PPAP, which stands for
production part approval process. Created and utilized first by the automotive
industry, PPAP is a risk identification and mitigation process used to provide evident to
the customer that there is a reliable and repeatable process. PPAP helps to ensure
better communication between a customer and supplier in hopes that there will be
fewer turnbacks and revisions to the product or process.

If you're not familiar or just want a quick overview, we've synthesized what you need to
know into a quick and easy breakdown of what PPAP is and does in the manufacturing
industry.

What is PPAP?
The Production Part Approval Process (PPAP) is a standardized process in the
automotive and aerospace industries that helps manufacturers and suppliers
communicate and approve production designs and processes before, during, and after
manufacture. PPAP is an output of APQP. Created in hopes to promote a clearer

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understanding of the requirements of manufacturers and suppliers, PPAP helps ensure

that the processes used to manufacture parts can consistently reproduce the parts at
stated production rates during routine production runs.

For those in the automotive industry, the PPAP process is currently governed by the
PPAP manual published by the Automotive Industry Action Group (AIAG). PPAP is one if
the 5 core tools of quality of the IATF 16949:2016 standard for the automotive sector
quality management systems.

Learn more about the 5 core tools of quality

What's included in a PPAP?

The PPAP manual is the ultimate resource for those in automotive supplier quality
management. The manual contains the PPAP checklist which includes all the
requirements, called elements, for a complete PPAP package.  The checklists identify
different PPAP levels (from 1 to 5). For those in the automotive industry, there are 18
possible elements that must be checked off. The aerospace industry has a similar set of
elements to be completed during the development, planning, and design of the
production process.

Each PPAP level determines the specific requirements for each element and indicates
which elements should be submitted to the customer. It is important to note, however,
that the supplier, regardless of PPAP level, must complete every applicable element no
matter what level the PPAP is.

Download Now: PPAP 101 Whitepaper

What are the required PPAP elements?

Automotive Elements 

1. Design records
2. Engineering Change Documents
3. Customer Engineering Approval
4. Design Failure Mode and Effects Analysis (DFMEA)
5. Process Flow Diagrams
6. Process Failure Mode and Effects Analysis (PFMEA)
7. Control Plan (download our control plan template)
8. Measurement System Analysis (MSA) Studies
9. Dimensional Results
10. Material Performance Test Results
11. Initial Process Studies - Statistical Process Control (SPC)
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12. Qualified Laboratory Documentation

13. Appearance Approval Report (AAR)
14. Sample Product
15. Master Sample
16. Checking Aids
17. Records of Compliance with Customer-Specific Requirements
18. Part Submission Warrant (PSW)

Aerospace Elements (example, see explanation)

1. Released Production Drawings or Definition

2. Supplementary Product Requirement Documents
3. Production Purchase Order
4. DFMEA
5. Process Flow Diagram
6. PFMEA
7. Process Control Plan
8. Process Readiness Study
9. Initial Process Studies
10. Measurement System Analysis
11. Engineering Frozen Planning/Engineering Source Approval
12. Dimensional Reports
13. Functional Testing Approval
14. Special Process Approval & NDT
15. Material Certification Documentation
16. Raw Material Approval
17. Part Marking Approval
18. Packaging, Preservation and Labeling Approval
19. Review and Sign-Off

It should be noted that there is no standardized aerospace PPAP like there is in the
automotive industry. Other companies are also working on developing their own
requirements for PPAP which their customers will need to use. Many of the elements
are the same as UTC's, but some are different. When AS9100, the aerospace quality
management system, moves from Rev C to Rev D, minimum requirements for
aerospace PPAP will be established that manufacturers will need to follow.

Why is PPAP negotiation necessary?

The Production Part Approval Process (PPAP) is similar to a work plan or strategy; it is
the direct negotiation between the customer and supplier that confirms how each
PPAP element is satisfied. Not every PPAP is the same, therefore negotiation must take
place before the requirement is accepted and the process put into motion. This
ensures that both parties have the same expectations. In many cases, the supplier will
have an established report, like a control plan, FMEA, or MSA that will help guide the
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customer through the supplier's process. If found acceptable to the customer, many
times these documents are duplicated and used by the supplier again.

When is a PPAP required?

A Production Part Approval Process (PPAP) is required anytime a new part of change to
an existing part or process is being planned. A customer may request a PPAP at any
time during the life of a product. For suppliers, this means maintaining a quality system
that develops and documents all of the requirements of a PPAP submission, no matter
if you have been asked to deliver one, is a must. Customers are not responsible for
creating PPAPs, suppliers are.
RGBSI not only provides PPAP services, but has also developed a PPAP automation
software. For more information, request a PPAP consultation through the form below.

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Need help with PPAP?

At RGBSI, we provide solutions for complete PPAP management. Let's discuss your needs.

 
First name* Last name*

Company email* Phone number*

Company name*

Job title Industry

Type of PPAP(s) to service?*

(Select all that apply)

Supplier PPAP
Customer PPAP
PPAP annual validation
Don't know

Type of Support*
(Select all that apply)

Onsite
Offsite

PPAP submission level(s)?*

(Select all that apply)

Level 1
Level 2
Level 3
Level 4
Level 5

Number/frequency of PPAPs per year?

Additional comments

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