Production Part Approval Process (PPAP)

1. Production part approval process (PPAP) [1] is used in 6. Process Failure Modes and Effects Analysis
the automotive supply chain for establishing confidence in (PFMEA)
component suppliers and their production processes, by 7. Control Plan
means of demonstrating that "All customer engineering 8. Measurement Systems Analysis (MSA)
design record and specification requirements are properly 9. Dimensional Results
understood by the supplier and that the process has the 10. Records of Material / Performance Test Results
potential to produce product consistently meeting these 11. Initial Process Studies
requirements during an actual production run at the 12. Qualified Laboratory Documentation
quoted production rate." 13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
Although individual manufacturers have their own
16. Checking Aids
particular requirements, the Automotive Industry Action
17. Customer-Specific Requirements
Group (AIAG) has developed a common PPAP standard as
18. Part Submission Warrant (PSW)
part of the advanced product quality planning (APQP) – and
encouraging the use of common terminology and standard 5. PPAP Examples
forms to document project status. The result of this process
is a series of documents gather ed in one specific location (a 5.1.1 Process Flow Example
binder or electronically) called the "PPAP Package". The
PPAP package is a series of documents which need a formal
approval by the supplier and customer. The for m that
summarizes this package is called PSW (part submission
warrant). The approval of the PSW indicates that the
supplier responsible person (usually the Quality Engineer)
has reviewed this package and that the customer has not
identified any issues that would prevent its approbation.

2. Applicability of PPAP [2]

Whenever Customer or Supplier under following

manufacturing phase, PPAP is required.

(1) New Part (2) Engineering Change (3) Tooling: Transfer,
Replacement, Refurbishment (4) Correction of Discrepancy
(5) Tooling Inactive > 1 Year (6) Change to optional
construction or material (7) Sub-supplier or material source
change (8) Change in part-processing (9) Parts produced at
new or additional location.
Figure 1 PPAP Process Flow Example [3]
5.1.2. PPAP documentation example
From following PPAP template, it is understood that how
NCR r equires to maintain PPAP from part supplier at
different level.

3. Benefits of PPAP [2]

PPAP Levels for Submission & Retention

(1) Helps to maintain design integrity (2) Identifies issues Requirement Level 1 Level 2
Submission Level
Level 3 Level 4 Level 5
early for resolution (3) Reduces warranty changes and cost 1. Design Records of Saleable Product R R R * R
of poor quality (4) Assist with managing supplier changes a. For proprietary components/details
b. For all other components/details
R
R
R
R
R
R
*
*
R
R
(5) Prevents use of unapproved and uncomfortming parts 2. Engineering Change Documents, if any
3. Customer Engineering approval, if required
R
R
S
S
S
S
*
*
S
S

(6) Identifies suppliers that need more improvement (7) 4. Design FMEA
5. Process Flow Diagrams
R
R
R
R
R
S
*
*
R
S

Improves overall quality of the product and customer 6. Process FMEA

7. Dimensional Results
R
S
R
S
S
S
*
*
S
S
8. Material, Performance, Test Results R S S * S
satisfaction. 9. Initial Process Study R R R * R
10. Measurement System Analysis Studies R R S * S
11. Qualified Laboratory Documentation R R S * S

4. Official PPAP Requirements [2] 12. Control Plan

13. Part Submission Warrant (PSW)
R
S
R
S
S
S
*
*
S
S
14. Appearance Approval Report, (AAR) if applicable S S S * S
15. Bulk Material Requirements Checklist (for bulk
Following documents should be submitted or retained by material only)
16. Sample Product
R
R
R
S
R
S
*
*
R
S
organization to customer at different levels of PPAP. 17. Master Sample
18. Checking Aids
R
R
R
R
R
R
*
*
R
R

Organization’s quality level and Customer’s requirement 19. Records of compliance with Customer-Specific
Requirements (DVP&R) R R R * R

will define the requirement of level. S = The supplier shall submit to NCR and retain a copy of records or documentation items at appropriate locations.

R = The supplier shall retain at appropriate locations and make readily available to NCR upon request.
1. Design Records * = The supplier shall retain at appropriate locations, and submit to NCR upon request. NCR will identify what is
needed for submission.
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required PLEASE CONTACT YOUR SUPPLIER QUALITY ENGINEER WITH ANY QUESTIONS .

4. Design Failure Modes and Effects Analysis

(DFMEA) applied in special situations
Figure 2 PPAP Levels for Submission/Retention [2]
5. Process Flow Diagram
6. Chrysler Case Study [4] 6.2. Mopar – Quality Part Management

By this case study it is understood that how Chrysler LLC is
using PPAP for quality supply chain management. Chrysler
requires Organizations to submit production and/or service
part approvals in accordance with PPAP guidelines.
6.1 Chrysler’s Requirement in accordance with PPAP
6.1.1. Submission Levels
Mopar is the parts, service and customer care organiza tion
within Chrysler Group LLC. Mopar also designs and builds a
small number of customized vehicles.
Following table illustrates under certain manufacturing
phases Mopar’s PPAP requirements to be followed by
supplier organization.

Organizations providing parts to a Chrysler Assembly plant

follows the guidelines for Submission Level 4.

Organizations providing certain designated parts to a

Chrysler Component or Powertrain plant follow the
guidelines for Submission Level 2, or as otherwise specified
by the rec eiving plant.

In cases where Chrysler requires a bulk material

submission, the organization takes reference from the bulk
material section in the PPAP manual.

6.1.2. Submission to Customer (Chrysler)

Organizations preparing a PPAP submission for

PRODUCTION PARTS designated for use at any Chrysler
production facility completes and retain a PSW in
a o da e with Ch ysle ’s e ui e e ts.
6.1.3. Che cking Aids
Checking aids shall be submitted when required to perform
dimensional inspection of the part being submitted.
6.1.4. Appe arance and Approval Report
Organizations are required to complete a Chrysler
Appearance Approval Report if the design records include
any appearance features (e.g. Colour, Grain, Finish,
Appearance Standards, or Mastering Standards). Prior to
completion of the PSW, organizations shall obtain a
Chrysler Product Design Office approval signature on the
AAR.
6.1.5. Interim Approval Authorization
The Interim Approval Authorization (IAA) is an official
document approved by Chrysler to allow interim approval
and shipment of parts which do not fully meet all PPAP
requirements. In cases where interim approval is granted,
the organization will receive an approved IAA from Chrysler
authorizing shipment for a limited time or a specified
quantity of parts.
7. Conclusion
The auto industry giants like Ford, Chrysler, GM and their
vast network of suppliers strictly adhere to the
PPAP. Initially developed by AIAG (Auto Industry Action
Group), PPAP has now spread to just about every other
industry. PPAP is used to formally reduce risks prior to
product or service release, in a team oriented manner using
well established tools and techniques. Both product launch
and any part revision (with a change in the manufacturing
process) require PPAP submission. In addition, each part
must be annually recertified. Of course, this means up-front
supplier training and developmental costs as well as small
on-going maintenance costs associated with PPAP.
References
[1] Citations from www.wikipedia.com
[2] PPAP Training Presentation of NCR
[3] PPAP 4th Edition – March 2006 – AIAG
[4] Chrysler Group LLC Customer Specific Requirements for
use with PPAP.

6.1.6. Third Party Laboratory

O ga izatio s ot desig ated y Ch ysle as PPAP “elf –

Ce tified a e e ui ed to use a I“O/IEC 7 5 a edited
third party laboratory to verify dimensional and
material/functional tests prior to completion of a PSW.