PPAP is the production part approval process used to demonstrate that suppliers can consistently meet engineering and customer requirements.
Definition
PPAP, or Production Part Approval Process, is a structured submission and approval method used to show that a production process can make parts that meet design records, specifications, and customer requirements at the intended production rate.
It typically includes design records, process flow, PFMEA, control plan, MSA, dimensional results, material and performance records, capability evidence, appearance approval when applicable, sample parts, and a Part Submission Warrant.
History
PPAP is rooted in automotive quality systems and AIAG guidance. It supports APQP by confirming that product and process planning have produced a capable production process before full release.
When to Use
Use PPAP for new parts, engineering changes, supplier changes, tooling moves, material changes, process changes, or customer-required reapproval events. The required submission level depends on customer requirements and risk.
Step-by-Step
- Confirm customer-specific PPAP requirements and submission level.
- Review design records, specifications, and special characteristics.
- Complete process flow, PFMEA, and control plan.
- Validate measurement systems and capability where required.
- Run production trial using intended tooling, materials, people, and rate.
- Collect dimensional, material, performance, and appearance evidence.
- Prepare samples and Part Submission Warrant.
- Submit, respond to feedback, and maintain approved records.
Examples
- New supplier: A machined bracket is submitted with dimensional layout and capability data.
- Tool move: A molded part needs evidence after production relocates.
- Engineering change: A revised drawing dimension triggers updated PPAP records.
Common Pitfalls
- Treating PPAP as paperwork after launch instead of evidence of readiness.
- Weak linkage between PFMEA, control plan, and measurement studies.
- Using prototype data instead of production-intent data.
- Missing customer-specific requirements.
- No change-control trigger for reapproval.
- Incomplete special-characteristic controls.