Understanding PPAP in Manufacturing
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SHIVENDRA PRATAP SINGHUnderstanding PPAP in Manufacturing
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SHIVENDRA PRATAP SINGHAshutosh Patil
What is PPAP?
• Developed by AIAG
• Standardized process in automotive and
manufacturing industries
• Ensures supplier's production process
consistently meets customer requirements
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Purpose of PPAP
• Demonstrate part conformity
• Confirm production readiness
• Ensure design requirements are understood
and met
• Prevent quality issues at launch
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When is PPAP Required?
• New part introduction
• Engineering design changes
• Tooling change (replacement, refurbishment,
transfer)
• Manufacturing process change
• Production location change
• Supplier change or sub-supplier change
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PPAP Submission Levels
1. PSW Only
2. PSW + limited supporting data
3. PSW + product samples + complete supporting data
4. PSW + other requirements as defined by customer
5. PSW + complete data with on-site review
Ashutosh Patil
PPAP Design Records
1. PSW Only
2. PSW + limited supporting data
3. PSW + product samples + complete supporting data
4. PSW + other requirements as defined by customer
5. PSW + complete data with on-site review
Ashutosh Patil
List of 18 PPAP Elements
1 Design Records 10 Records of Material
2 Engineering Change Documents 11 Initial Process Studies
3 Customer Engineering Approval 12 Qualified Laboratory Document
4 Design FMEA 13 Appearance Approval Report
5 Process Flow Diagram 14 Sample Production Parts
6 Process FMEA 15 Master Sample
7 Control Plan 16 Checking Aids
8 Measurement System Analysis 17 Customer-Specific Requirements
9 Dimensional Results 18 Part Submission Warrant (PSW)
Ashutosh Patil
PPAP Submission Levels
1. PSW Only
2. PSW + limited supporting data
3. PSW + product samples + complete supporting data
4. PSW + other requirements as defined by customer
5. PSW + complete data with on-site review
Ashutosh Patil
1. Design Records
• Complete drawing or CAD file
• Must reflect latest design level
• Include part number and revision level
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2. Authorized Engineering Changes
• Change notices approved by the customer
• Must be reflected in design records
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3. Customer Engineering Approval
Evidence of trial runs or tests approved by customer
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4. Design FMEA (DFMEA)
• Risk analysis at design level
• Identifies potential failure modes
• Assesses severity, occurrence, and detection
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5. Process Flow Diagram
• Visual representation of manufacturing process
• Should match Control Plan and PFMEA
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6. Process FMEA (PFMEA)
• Visual representation of manufacturing process
• Should match Control Plan and PFMEA
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7. Control Plan
• Lists controls for key product/process
characteristics
• Includes control methods, frequencies, and
responsibilities
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8. Measurement System Analysis (MSA)
• Gage R&R studies
• Ensures accuracy and reliability of measurement
systems
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9. Dimensional Results
• Report of measurements for all dimensions on the
drawing
• Minimum 6 parts typically measured
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10. Material / Performance Test Results
Validation of physical, chemical, or performance
characteristics
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11. Initial Process Studies
Statistical analysis (Cp, Cpk) of critical
characteristics
Demonstrates process stability and capability
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12. Qualified Lab Documentation
Certifications of any external test laboratories used
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13. Appearance Approval Report (AAR)
Required for parts with visual/appearance
specifications
Signed by customer design/quality personnel
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14. Sample Production Parts
• Representative samples from production run
• Labeled and stored for reference
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15. Master Sample
• Retained at supplier site
• Used for training and inspection
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16. Checking Aids
• Gages, fixtures, templates used in production
• Include calibration records
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17. Customer-Specific Requirements
• May vary by OEM (e.g., Ford, GM, Stellantis)
• Always check customer manuals
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18. Part Submission Warrant (PSW)
• Summary document confirming all elements are
complete
• Signed by responsible supplier personnel
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