Production Part Approval Process (PPAP)

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📘 1. What Is PPAP?

PPAP stands for Production Part Approval Process. It is a formal process defined by the Automotive Industry Action Group (AIAG) to ensure that parts supplied by vendors meet customer requirements before mass production begins.

PPAP is part of the Core Tools (alongside APQP, FMEA, MSA, SPC) and supports compliance with IATF 16949.

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📅 2. When Is PPAP Required?

According to AIAG, PPAP submission is required in the following cases:

• New product or part introduction
• Design or engineering change
• Supplier or material source change
• Production process change
• Tooling transfer, replacement, or modification
• Manufacturing location change
• Restart after extended shutdown
• Customer request (audit or quality issue)

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🎯 3. The Purpose of PPAP

PPAP ensures that:

• The product meets all specifications
• The manufacturing process is capable and stable
• The documentation is complete and aligned
• The customer can approve the part with confidence

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📦 4. The 18 Elements of PPAP (AIAG Standard)

Below is a list of the 18 required elements for a Level 3 PPAP submission:

#	Element	Description
1	Design Records	2D/3D drawings, CAD models
2	Engineering Change Documents	Change request or approval
3	Customer Engineering Approval	For test validation (if required)
4	DFMEA	Design Failure Mode & Effects Analysis
5	Process Flow Diagram	Visual map of production steps
6	PFMEA	Process FMEA – risk identification
7	Control Plan	Defines control methods and checks
8	MSA	Gage R&R, bias, linearity, stability
9	Dimensional Results	Measurements from sample parts
10	Material / Performance Test Results	Properties, standards compliance
11	Initial Process Studies	Cp, Cpk for key characteristics
12	Qualified Laboratory Documentation	Accreditation certificates
13	Appearance Approval Report (AAR)	For parts with visual requirements
14	Sample Production Parts	Marked and shipped to customer
15	Master Sample	Archived reference part
16	Checking Aids	Fixtures or gauges used
17	Customer-Specific Requirements	OEM or Tier-1 specific rules
18	Part Submission Warrant (PSW)	Formal declaration of conformity

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🧾 5. PPAP Submission Levels Explained

AIAG defines five submission levels:

Level	What’s Required	Typical Use Case
Level 1	PSW only	Non-critical service parts
Level 2	PSW + limited elements	Minor changes
Level 3	PSW + all elements	Default level
Level 4	PSW + as requested by customer	Custom cases
Level 5	All documents + customer audit	Critical parts or high-risk suppliers

💡 Note: Unless specified otherwise, Level 3 is usually expected.

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📝 6. The Role of the PSW

The Part Submission Warrant (PSW) is the core document in any PPAP package. It certifies that:

• All PPAP elements have been completed and reviewed
• Parts meet customer and design specifications
• The supplier is ready for series production

The PSW must be signed by the supplier and submitted to the customer for approval.

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🌍 7. AIAG vs VDA PPAP: Key Differences

Feature	AIAG PPAP	VDA PPA
Region	North America	Germany / Europe
Focus	Documentation and capability	Risk-based & maturity model
Submission	Part Submission Warrant (PSW)	Sampling and function testing
Standard Used	AIAG PPAP Manual (4th edition)	VDA Volume 2

If you supply global OEMs, understanding both systems is often required.

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📈 8. Best Practices for a Successful PPAP

✅ Start early in the APQP phase
✅ Align internal documents: DFMEA, PFMEA, Control Plan
✅ Use calibrated tools and validated measurement systems
✅ Involve engineering, production, and quality teams
✅ Use digital templates to avoid document errors
✅ Communicate proactively with the customer

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⚠️ 9. Common Mistakes to Avoid

❌ Submitting prototype data instead of production data
❌ Missing test reports or MSA studies
❌ Submitting incomplete or outdated FMEAs
❌ Using non-accredited labs for validation
❌ Skipping customer-specific requirements

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✅ 10. Final Thoughts

PPAP is much more than a checklist—it’s a guarantee that your product and process are ready for launch. A well-executed PPAP demonstrates professionalism, builds trust with your customers, and ensures long-term quality compliance.

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