Quality Management System Procedures
Procedure for Production Part Approval Process
PPPL-QP-07
1. Purpose: The purpose of production part approval is to determine if all customer
engineering record and specification requirements are properly understood and the
process has the potential to produce the product meeting these requirements.
2. Scope: The procedure is applicable only for the products manufactured for all
customers of PPPL. Production part review & approval is required for each part prior to
the first quantity shipment in the situations as described in “when submission is
required”
3. Responsibility:
HOD - QA is responsible for PPAP.
4. Process :
Customer’s PPAP requirements are recd. To Customer specific PPAP
develop a new product as per his design & drawing. Requirements.
If customer does not specify his specific PPAP PPPL method for PPAP
requirements, PPPL notifies its PPAP method being requirements as per
used as per IATF 16949:2016. IATF 16949: 2016
Production parts are manufactured at the production
site using the production tooling, gauging, process,
materials, operators, environment and the process
settings.
Parts for production part approval shall be taken
from a significant production run. This run would
typically be from one hour to one shift, production
as customer has agreed upon required quantity in
writing.
Quality Management System Procedures
Procedure for Production Part Approval Process
PPPL-QP-07
Production Part Approval Process (PPAP) shall be required for each
part prior to the first quantity shipment in the situations mentioned
below;
A new part or product (i.e.. a specific part/material not previously
supplied to the specific customer)
Correction of a discrepancy on a previously submitted part.
Product modified by an engineering change to design records,
specifications or materials.
Based on the contractual requirements between the supplier and the
customer, the necessary information is made available to the
concerned function.
Use of another construction material than used in the previously
approved part.
Production from new or modified tools (except perishable tools, dies
including additional or replacement tooling)
Production following refurbishment or rearrangement of existing tooling
or equipment.
Production following any change in process or method of manufacture.
Production from tooling & equipment transferred to a different plant
location or from an additional plant location.
Change of source for sub-contracted parts, materials or services.
Product pre-released after the tooling has been inactive for volume
productions for 12 months or more, if customer demanded.
Following a customer request to suspend shipment due to PPPL quality
concern.
All the above changes / conditions of submission of PPAP requires
customer notifications and customer approval (when specified)
1. Change in test / inspection method – new technique. (no effect on
acceptance criteria)
The purpose of these requirements is to identify changes that might affect
the direct customer or ultimate purchaser of the vehicle or component.
Any additional requirement for verification stages, when requested by
customer shall be met.
The documents / items listed below shall be completed and submitted with each part
when any of the situations mentioned above occurs. Direction on which of these items
must be provided to the customer shall be as per the submission level decided.
Design record
Any authorized engineering change documents.
Engineering Approval when required.
Process Flow diagram.
Process Failure Mode and Effect Analysis.
Dimensional Results.
Record of Material/ Performance test results.
Initial Process studies.
Measurement System Analysis studies
Quality Management System Procedures
Procedure for Production Part Approval Process
PPPL-QP-07
The customer shall identify the submission level that will be used.
The submission levels are:
LEVEL 1 : Warrant only submitted to the customer
LEVEL 2 : Warrant with product samples and limited supporting data submitted to the
Customer.
LEVEL 3 : Warrant with product samples and complete supporting data sent to the
Customer.
LEVEL 4: Warrant (no product samples) with complete supporting data submitted to
the customer.
LEVEL 5: Warrant with product samples & complete supporting data reviewed at
PPPL manufacturing unit
If customer doesn’t specify any levels of submission, PPPL by default shall follow
LEVEL 3.
PPAP with Suppliers
Production Part Approval process for Suppliers can be classified basically into two
categories;
Complete PPAP (level 3)
PAP - Minimum of PSW, Specifications, Test Reports (Dimensional, Material,
Performance, Appearance - If applicable)
a) In case of customer specific requirements of PPAP with subcontractors, PPAP level 1
will be conducted until and unless level specified by the customer.
b) PAP is conducted for all only ISO/TS certified Raw Material supplier.
Quality Management System Procedures
Procedure for Production Part Approval Process
PPPL-QP-07
Whenever a sub-contractor declares an item to be proprietary in nature and does not
provide for PPAP / PAP purposes but it is made available for inspection at his premises -
PPPL shall, during their scheduled vendor audit conduct for these aspects. The records of
the audit providing objective evidence will be made a part of the PPAP / PAP file.
PPAP / PAP with direct material sub-contractor will be fear off in the following situations -
Change of source of any direct material
Change of grade of direct material.
Change in specifications proposed by PPPL or supplier.
Indirect material
All test reports related to material & performance parameter shall accompany for any new
indirect material.
5. Documents :
All required PPAP Document
6. Records :
Quality Management System Procedures
Procedure for Production Part Approval Process
PPPL-QP-07
All required PPAP Records