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The Production Part Approval Process (PPAP) helps ensure a supplier’s manufacturing process consistently produces parts that meet your design specifications. PPAP is one of the core tools within Advanced Product Quality Planning (APQP), a structured approach to designing, developing, and launching quality products.
PPAP is complex, but it can provide you with proof that the manufactured parts you receive meet your requirements. Keep reading to learn more, beginning with some PPAP basics and an overview of the PPAP process. You’ll then learn about PPAP levels, documentation requirements, best practices, and frequently asked questions (FAQs).
PPAP provides proof that you’re getting quality parts. Image Credit: ChainTraced
Important: Fictiv supports PPAP, but we also provide quality parts outside of this framework. If your project requires PPAP, select it as an additional service when you request a quote for Injection Molding, CNC Machining, or one of the other services we provide.
You can specify PPAP when you request a quote from Fictiv. An additional fee applies.
PPAP Basics
PPAP is used primarily by the automotive and aerospace industries. However, it also has applications in electronics manufacturing and the production of consumer goods.
The Automotive Industry Action Group (AIAG) developed PPAP, and it’s now used by original equipment manufacturers (OEMs) including Stellantis, Ford Motor Company, General Motors, Boeing, and Airbus. Tiered suppliers to these and other OEMs also use PPAP.
There are strong arguments for using PPAP. “Through PPAP, the supplier and customer agree upon the requirements needed to obtain approval of the supplier-manufactured parts,” explains Lisa Wang, Deputy General Manager and Head of Quality for Fictiv in China. “By providing a consistent approval process, PPAP also helps to reduce delays and non-conformances.”
PPAP has its advantages, but there are also potential disadvantages to consider.
Advantages of PPAP in Manufacturing
PPAP provides suppliers and their customers with these advantages:
- Quality Assurance: Manufactured parts meet well-defined requirements. In addition, the documentation that PPAP requires promotes part-to-part consistency.
- Improved Supplier-Client Relationships: Suppliers who demonstrate their ability to meet customer requirements build trust. PPAP also clarifies expectations about quality.
- Process Control: The stable production environment that PPAP requires reduces the likelihood of manufacturing issues.
- Cost and Risk Reduction: By reducing part defects and non-conformities, PPAP helps to reduce costs and avoid product recalls.
Disadvantages of PPAP in Manufacturing
Despite its strengths, PPAP comes with some disadvantages:
- High Resource Dependency: Implementing PPAP can require significant upfront investments in quality control, testing, and documentation.
- Complexity: PPAP can involve a large number of documents and steps, which adds complexity to the internal processes of suppliers and their customers.
- Increased Workload: Managing the documentation and data that’s involved can be time-intensive and may require dedicated personnel.
- Rigidity: PPAP has a formalized structure that may seem overly rigid to companies that are not part of the automotive or aerospace industries.
Following a process like this is necessary, but creating a flowchart is not a PPAP requirement. Source: AIAG.
Overview of the PPAP Process
PPAP is a structured process where both the supplier and the customer have responsibilities.
The list below summarizes them.
- Pre-Planning and Initial Steps: The customer specifies a PPAP submission level, and the supplier analyzes the customer’s requirements and confirms its ability to meet them. See the “PPAP Submission Levels” section in this article for more information.
- Design: The supplier gathers all design records (such as CAD files) from the customer. Later, if the customer changes the design, the supplier must document the implementation of these changes.
- Process Development: The supplier creates a process flowchart, performs a process failure mode and effects analysis (PFMEA), and develops a Control Plan that describes how it will monitor and control the quality of products and processes.
- Measurement and Testing: The supplier produces part samples, measures part dimensions, performs materials and performance testing, and compares this data to the customer’s specifications.
- Preliminary Process: The supplier runs a batch of sample parts under production conditions to gather data about the manufacturing process. With injection molding, for example, this involves using the same mold, material, and machine as the supplier will use during production.
- Documentation and Submission: The supplier prepares a PPAP Package with up to 18 different documents, depending on the PPAP submission level. See the “PPAP Requirements” section for descriptions of this information.
- Customer Review and Approval: The customer reviews the supplier’s PPAP submission and provides either full or conditional approval. Alternatively, the customer can reject the submission.
- Approval and Production: After receiving approval from the customer, the supplier begins production.
- Post-Approval Monitoring: The supplier monitors its production process, checks parts periodically, and makes adjustments as necessary.
PPAP and Part Sampling
During production runs, PPAP involves the random selection and inspection of parts to demonstrate the compliance of the entire batch. “The sample size should be statistically significant, often determined by customer requirements or industry standards,” explains Lisa Wang, Deputy General Manager and Head of Quality for Fictiv in China.
“For Fictiv”, she adds, “significant production runs are between one to eight hours of production, with a minimum production quantity total of 300 consecutive parts, unless otherwise specified by the authorized customer representative.”
PPAP Submission Levels
With PPAP, the customer specifies one of five submission levels. In turn, the specified level determines what the supplier must submit to the customer.
All PPAP levels require a Part Submission Warrant (PSW), a formal declaration that the supplier has completed all PPAP requirements and that the production process is capable of consistently producing parts that meet all specifications.
The table below describes the five PPAP levels in terms of what the supplier submits.
| PPAP Level | What the Supplier Submits |
| Level 1 | PSW |
| Level 2 | PSW with limited supporting documentation |
| Level 3 | PSW with complete supporting documentation. Note: This level has the most elements |
| Level 4 | PSW and proof of compliance with other customer requirements. |
| Level 5 | PSW with product samples and complete supporting documentation available for review at the supplier’s location. |
PPAP Requirements
The PPAP Reporting Package can contain up to 18 elements, including the PSW.
The table below describes them.
| No. | Element | Description |
| 1 | Design Documentation | Includes detailed drawings, CAD files, and specifications that define the part’s design, ensuring all aspects of the part’s geometry and materials are documented. |
| 2 | Engineering Change Documentation | Documents any changes to the design or process, including the rationale and impact on the part, ensuring all modifications are tracked and approved. |
| 3 | Customer Engineering Approval | The customer’s engineering team verifies the design for compliance and provides approval. |
| 4 | Design Failure Mode and Effects Analysis (DFMEA) | Analyzing potential design failures can preemptively address issues and improve reliability. |
| 5 | Process Flow Diagram | A step-by-step visual representation of the entire manufacturing process, highlighting critical stages and control points. |
| 6 | Process Failure Mode and Effects Analysis (PFMEA) | Identifies potential failure modes in the manufacturing process, their causes and effects, and the actions taken to mitigate risks. |
| 7 | Control Plan | Outlines the specific controls in place at each stage of the production process to ensure the part meets quality requirements consistently. |
| 8 | Measurement System Analysis (MSA) | Evaluates the accuracy and precision of the measurement systems used, including gauge R&R (Repeatability and Reproducibility) studies. |
| 9 | Dimensional Results (FAI) | Provides detailed records of measurements and tests performed on initial production parts, verifying they meet specified dimensions and tolerances. |
| 10 | Records of Material / Performance Tests | Includes test reports and certifications that confirm the materials and parts meet required performance standards and specifications. |
| 11 | Initial Process Studies (CPK – SPC Dimensions) | Summarizes the inspection results of initial sample parts, ensuring they conform to all design and quality requirements. |
| 12 | Qualified Laboratory Documentation | Provides certifications from laboratories that performed the tests, ensuring their methods and results are accurate and reliable. |
| 13 | Appearance Approval Report (AAR) | Documents the visual inspection of parts to ensure they meet the customer’s aesthetic requirements. |
| 14 | Sample Production Parts | Details the results of a production trial run, including any issues encountered and corrective actions taken to ensure the process can produce parts at the required quality level. |
| 15 | Master Sample | Approved part serving as a reference for future production, ensuring consistency. |
| 16 | Checking Aids | Tools and fixtures used for inspection and testing to ensure accurate and consistent results. |
| 17 | Customer-Specific Requirements | Records of Compliance: Documentation showing adherence to specific customer requirements. |
| 18 | Part Submission Warrant (PSW) | A formal declaration that the supplier has completed all PPAP requirements and that the production process is capable of consistently producing parts that meet all specifications. |
The following chart indicates the PPAP levels for which an element is required.
- R means the supplier retains the element (i.e., does not submit it to the customer)
- S means the supplier submits the element to the customer
- R&S stands for retain the element and submit to the customer upon request
This chart also indicates the submissions which Fictiv, as the supplier, performs. They are highlighted in green.
PPAP Requirements and Submission Levels
PPAP Best Practices
PPAP is complex, but following some best practices can help.
- Early Planning: Start planning for PPAP early in the product development cycle to avoid last-minute rushes.
- Cross-Functional Teams: Form cross-functional teams to handle different aspects of the PPAP process, ensuring comprehensive coverage.
- Training and Education: Provide training for all team members on PPAP requirements and best practices.
- Use of Technology: Use digital tools rather than manual “paper trails” to automate and streamline the PPAP process.
- Regular Audits: Conduct regular audits of PPAP documentation and processes to identify and address potential issues early.
- Continuous Improvement: Use execution experiences to update PPAP documentation such as PFMEA and Control Plans.
Common PPAP Challenges
Following PPAP best practices also involves recognizing common challenges before they become problems.
- Incomplete Documentation: Missing or incomplete documents can delay approval. A thorough review process ensures all required documents are included and accurate.
- Lack of Standardization: Variability in documentation and processes can lead to inconsistencies. Standardizing PPAP documentation and processes maintains consistency.
- Time-Consuming Processes: Manual processes can be time-consuming and prone to errors. It’s better to automate repetitive tasks and use digital tools.
- Communication Gaps: Poor communication between teams can result in misunderstandings and delays. Meet regularly to avoid this.
Cross-functional teams and clear communications strengthen PPAP.
Frequently Asked Questions about PPAP
The following sections provide answers to frequently asked questions (FAQs) about the Production Part Approval Process (PPAP).
What is the most challenging aspect of PPAP?
One of the most challenging aspects of PPAP is managing the extensive documentation and ensuring that all 18 elements are accurately completed on time. This requires attention to detail, effective communication between teams, and a clear understanding of the part quality requirements.
How does Fictiv streamline the PPAP process?
Fictiv’s digital platform automates the collection of part documentation, provides real-time tracking, and leverages data analytics. Plus, Fictiv Supplier Quality Engineers (SQE) work on-site with our Manufacturing Partners to ensure that PPAP is implemented completely and correctly. For the customer, this reduces the time and effort required for PPAP.
Do smaller companies benefit from PPAP?
Smaller companies will benefit by leveraging Fictiv’s SQE resources. It helps them establish robust quality control processes, reducing the risks and negative impacts that poor quality can have on production timelines and project costs.
What are the future trends in PPAP submission?
Future trends in PPAP submission include increased digitalization, integration with Industry 4.0 technologies, a focus on sustainability, and global standardization. These trends will enhance efficiency, accuracy, and collaboration in the PPAP process, helping manufacturers meet evolving industry demands and maintain high quality standards.
Does Your Project Require PPAP?
The Production Part Approval Process (PPAP) helps to ensure that a supplier’s manufacturing process can consistently produce parts that meet your design specifications. Fictiv supports PPAP, but we also provide quality parts outside of this framework. If your project requires PPAP, select it as an additional service when you request a quote from us. You’ll need to create a free Fictiv account first, but it’s a fast and easy process.