PPAP Process in Automotive Manufacturing
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Jinhua NiPPAP Process in Automotive Manufacturing
Uploaded by
Jinhua Ni- Production Part Approval Process (PPAP)
- Mopar Quality Part Management
- Chrysler Case Study
- Conclusion
Common questions
Powered by AIThe key components required for a PPAP package include Design Records, Authorized Engineering Change Documents, Customer Engineering Approval if required, DFMEA, Process Flow Diagrams, PFMEA, Control Plan, Measurement Systems Analysis, Dimensional Results, Records of Material/Performance Test Results, Initial Process Studies, Qualified Laboratory Documentation, Appearance Approval Report, Sample Production Parts, Master Sample, Checking Aids, Customer-Specific Requirements, and the Part Submission Warrant (PSW). These components are vital for quality assurance as they ensure all design and execution aspects are thoroughly analyzed and documented, thereby reducing the risk of defects and non-compliance with customer specifications .
PPAP helps maintain design integrity by ensuring that all component designs are thoroughly reviewed and tested against customer specifications, which prevents discrepancies and deviations . It improves supplier quality management by identifying issues early for resolution, reducing warranty changes, preventing the use of unapproved parts, and identifying suppliers that require improvement .
Chrysler applies PPAP guidelines by requiring Submission Level 4 for parts provided to Chrysler Assembly plants. For certain designated parts provided to Chrysler Component or Powertrain plants, Chrysler may require Submission Level 2 or another level as specified by the receiving plant. This differentiation ensures tailored quality control processes suitable for different plant types and their manufacturing needs .
The advantages of having a common PPAP standard by AIAG include fostering consistency across the automotive supply chain by using common terminology and standard forms, facilitating mutual understanding and cooperation between suppliers and manufacturers, and enhancing efficiency in the documentation and review process. Additionally, it helps reduce complexity and errors by following an industry-wide recognized framework .
Suppliers might face challenges such as increased upfront training and development costs, ongoing maintenance costs, and the complexity of preparing comprehensive documentation for PPAP compliance. To mitigate these challenges, suppliers can invest in continuous training programs, automate documentation processes where possible, and enhance communication with both upstream and downstream supply chain partners to ensure all aspects of production and change management align with PPAP requirements. Collaborating with experienced quality engineers and utilizing quality management software can also alleviate some of the burdens associated with PPAP compliance .
The Part Submission Warrant (PSW) summarizes the PPAP package and indicates that the responsible person, usually the Quality Engineer, has reviewed the entire package to ensure it meets the necessary product requirements and standards. The PSW is a formal acknowledgment by the supplier that the production process is capable of meeting customer specifications consistently .
The PPAP process contributes to reducing warranty changes and the cost of poor quality by ensuring that all aspects of the production process are evaluated and approved against stringent quality standards before mass production begins. This preemptive approach catches potential issues early, averting defective products from reaching customers and thereby decreasing the likelihood of warranty claims and associated costs .
A Design Failure Modes and Effects Analysis (DFMEA) is specifically applied in situations where design-related risks are anticipated. Its purpose is to systematically identify potential failure modes in a product design, assess the related effects on performance, and guide the design team in implementing preventive measures to mitigate these risks before they reach the customer .
A supplier might be required to use a third-party laboratory accredited under ISO/IEC 17025 to ensure impartial verification of dimensional and material/functional tests. Using an accredited third-party helps maintain objectivity and credibility in test results, as internal testing might be subject to bias or lack of resources. This external verification is especially required when suppliers are not designated as "PPAP Self-Certified" by the customer, thus necessitating rigorous impartial approval .
A PPAP submission is required under manufacturing phases such as New Part introduction, Engineering Change, Tooling: Transfer, Replacement, Refurbishment, Correction of Discrepancy, Tooling Inactive > 1 Year, Change in optional construction or material, Sub-supplier or material source change, Change in part-processing, and when parts are produced at a new or additional location . It is necessary in these cases to ensure that any changes or introductions do not compromise the product quality and to maintain consistency and compliance with customer requirements .
![Production Part Approval Process (PPAP)
1. Production part approval process (PPAP) [1] is used in
the automotive supply cha](/p?url=https%3A%2F%2Fscreenshots.scribd.com%2FScribd%2F252_100_85%2F356%2F618475154%2F1.jpeg&__src=https%3A%2F%2Fwww.scribd.com%2Fdocument%2F618475154%2FProduction-Part-Approval-Process-PPAP&__type=image)
![6. Chrysler Case Study [4]
By this case study it is understood that how Chrysler LLC is
using PPAP for quality supply chain](/p?url=https%3A%2F%2Fscreenshots.scribd.com%2FScribd%2F252_100_85%2F356%2F618475154%2F2.jpeg&__src=https%3A%2F%2Fwww.scribd.com%2Fdocument%2F618475154%2FProduction-Part-Approval-Process-PPAP&__type=image)