Production Part Approval Process (PPAP) in Simple Words
Basic Question & Answers -
What are the 5 core tools of Quality Management.
1. APQP (Advanced Product Quality Planning)
2. PPAP (Production Part Approval Process)
3. FMEA (Failure Mode & Effect Analysis)
4. SPC (Statistical Process Control)
5. MSA (Measurement System Analysis)
PPAP - Stands for "Production Part Approval Process".
It is one of the core tools of Quality Management.
PPAP is the outcome of APQP.
Who submits PPAP & to whom?
Suppliers submits PPAP to Customer.
When should supplier conduct PPAP?
When supplier is being produced a new Part -
When there is change in existing drawing that is called ECR -
When there is change in existing process, methods, materials -
What are the 18 Documents of PPAP -
1. Component / Part Drawing
2. ECR (Engineering Change Document)
3. Customer Engineering Approval
4. Design failure Mode & Effect Analysis
5. Process Flow Diagram
6. PFMEA (Process Failure Mode & Effect Analysis)
7. Control Plan
8. MSA Studies (Measurement System Analysis)
9. Dimensional Results
10. Material, Performance & Test Results
11. Initial Process Capabilities Studies
12. Qualified Laboratory Documents
13. Appearance Approval Report (AAR), if applicable
14. Sample Product
15. Master Sample
16. Checking Aids
17. Customer Specific Requirements
18. Part Submission Warrant (PSW)
What are levels of PPAP -
1. Part Submission Warrant (PSW) only submitted to customer.
2. PSW with product samples & limited supporting data.
3. PSW with product samples & complete supporting data.
4. PSW & other requirements as defined by customer.
5. PSW with product samples & complete supporting data available for review at the supplier's manufacturing location.
Note - Most of the suppliers & customer prefers level 3 & level 5.
AIAG publishes which current edition of PPAP?
Production Part Approval Process - 4th Edition.
What is the 'Qualified Laboratory Documents' in PPAP?
It consists of the industry certification for any lab that is involved in validation & testing of measuring & testing instruments / equipment. If supplier takes calibration facility from outside lab, NABL certification is one of the certificates which requires during PPAP submission.
Is AAR (Appearance Approval Report) mandatory for PPAP submission?
The AAR is applicable for components affecting appearance only. Mainly, it consists of component's color evaluation / texture evaluation. Example - Vehicle dashboard's component must require AAR during PPAP submission. Some chassis components may not require AAR. It depends on the Customer requirements.
When should supplier re-submits the PPAP?
1. PPAP rejected by Customer for new part.
2. Addition of manufacturing process in existing process.
3. Modification of existing manufacturing process.
4. Change or modification in manufacturing methods.
5. Shifting of machines from one place to another.
6. Change in raw materials.
7. Change in machine.
What is PSW (Part Submission Warrant)?
PSW includes the complete package of PPAP. It is the one pager document which consists of check list of PAPP documents, date of PPAP submission, level of PPAP, supplier sign, customer sign & PPAP acceptance etc.
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