Table of Contents

Production Part Approval Process: An In-Depth Guide

Introduction

When it comes to manufacturing and production, quality control is an essential aspect. The Production Part Approval Process (PPAP) is a crucial quality control procedure that helps ensure that a manufacturer’s production process can consistently produce products that meet customers’ specifications. This article will take an in-depth look at the PPAP process, including its purpose, benefits, and key steps.

What is the Production Part Approval Process (PPAP)

PPAP defines the approval process for new or revised parts or parts produced from new or significantly revised production methods. The PPAP process consists of 18 elements that may be required to approve production-level parts. Not all of the elements are required for every submission. There are five generally accepted PPAP submission levels. The PPAP manual contains detailed information, guidelines and sample documents useful for completing the process requirements. The resulting PPAP submission provides evidence that the supplier has met or exceeded the customer’s requirements and the process can consistently reproduce quality parts.

OR,

The Production Part Approval Process (PPAP) is a standardized process in the automotive industry but is also widely used in other industries. The PPAP process is a quality control process that helps manufacturers ensure that their production process can consistently produce products that meet customers’ specifications.

Who does the PPAP, and when is It required?

Suppliers or the production team create the PPAP report for the customer to review. The process is usually done closely with the OEM’s quality team.

PPAP is typically required for the production of new parts or when there is a change to the product or process:

A new part or product.
Product changes/corrections: design, materials, supply, and function.
Process changes/corrections: method, tools, location, and inspection criteria.
Inactive tooling for more than one year

Why Perform Production Part Approval Process (PPAP)

The PPAP process verifies that the supplier understands all customer engineering design specifications and requirements and that the process can consistently produce products meeting those requirements during an actual production run at the quoted production rate. PPAP and other quality tools continue to be implemented in more industries; therefore, it is important to understand the PPAP requirements to remain competitive as a parts supplier.

Purpose of PPAP

The primary purpose of PPAP is to ensure that customers receive products that meet their specifications. PPAP is an essential tool that helps manufacturers identify and eliminate potential problems early in production, reducing the risk of product failure or customer complaints.

Benefits of PPAP

There are several benefits of implementing PPAP in the production process. These include:

Early problem identification: PPAP helps manufacturers identify potential problems early in production, reducing the risk of product failure or customer complaints.
Cost reduction: By identifying potential problems early, manufacturers can reduce costs associated with correcting problems after production.
Improved customer satisfaction: PPAP helps ensure that customers receive products that meet their specifications, improving customer satisfaction.

What’s in a PPAP Document

The PPAP report reviews 18 requirements called elements.

18 Elements of PPAP

1. Design Documentation

A part is a drawing that the customer usually provides. Every feature on the part drawing must be ballooned (or bubbled) to correspond with the inspection results. This includes print notes, standard tolerance notes and specifications, and anything else relevant to the part’s design.

Why include a copy of the part drawing in your PPAP?

It shows your customer you have a copy of the part drawing and ensures you are both discussing the same part.

2. Engineering Change Documentation

A document that shows a detailed description of the change is usually called an “Engineering Change Notice”. This document is only required if there is a change.

3. Customer Engineering Approval

This approval is usually the engineering trial with sample production parts performed by the customer. A “temporary deviation” is often required to send parts to the customer before the complete PPAP. Your customer may require other additional engineering approvals.

4. Design Failure Mode and Effect Analysis (DFMEA)

Design Failure Mode and Effect Analysis (DFMEA) is an application of the Failure Mode and Effects Analysis (FMEA) specific to the design stage. The DFMEA allows the design team to document what they predict about a product’s potential failures before completing a design and use this information to mitigate the causes of failure.

5. Process Flow Diagram

The Process Flow Diagram shows all the steps required to manufacture the part. It should include all of the main steps in processing the part, including incoming components, measuring, and inspection. The Process Flow Diagram should match the control plan and the Process Failure Mode and Effects Analysis (PFMEA) and also includes the flow of non-conforming materials and parts.

6. Process Failure Mode and Effects Analysis (PFMEA)

Process Failure Mode and Effects Analysis (PFMEA) evaluates each step in the production process to indicate what could go wrong during the fabrication and assembly of each part.

7. Control Plan

The Control Plan mirrors the PFMEA (Process Failure Mode and Effects Analysis). It provides more details on how potential issues are checked in the incoming inspection, assembly process, or during the inspection of the finished part. 8. Measurement System Analysis Studies

The Measurement Systems Analysis study will conform to the customer’s relevant ISO or TS standard. Typically it includes the Gauge R&R (Gauge Repeatability and Reproducibility) for the critical characteristics, and a confirmation that gauges used to measure these characteristics are calibrated.

9. Dimensional Results

A list of every dimension on the ballooned part drawing and measurement results. This list includes the product characteristic, specifications, measurement results, and assessment showing if the dimension “passed” or “failed”. Typically a minimum of 6 pieces are reported per product.

10. Records of Material / Performance Tests

A summary of all tests that have been performed on the part. The summary should document any pass or fail inspection results. The customer and the supplier should sign it off to show that all required tests have been done and any additional data for tests have been submitted.

11. Initial Process Studies

Generally, this includes SPC (Statistical Process Control) charts for critical characteristics. These studies demonstrate that the critical processes are stable and are ready to begin the process validation builds.

12. Qualified Laboratory Documentation

Includes all of the industry certifications for any lab completing validation testing.

13. Appearance Approval Report (AAR)

The Appearance Approval Report verifies that the customer has inspected the final product and it meets all the required appearance specifications for the design. The report includes color, textures, fit (gaps between parts), etc.

14. Sample Production Parts

A picture of the production parts is included in the PPAP documentation, along with the location where the parts are stored.

15. Master Sample

A sample part that the customer and supplier sign off. The master part is normally used to train operators on subjective inspections such as visual or noise.

16. Checking Aids

Checking aids are used by production and are a detailed list of all the tools used to inspect, test or measure parts during the assembly process. This aid will list the part, describe the tool, and have the calibration schedule for the tool.

17. Records of Compliance with Customer-Specific Requirements

This section of the PPAP requirements is where each customer lists their specific requirements for the PPAP process.

18. Part Submission Warrant (PSW)

This is a summary of the entire PPAP submission and specifies the following:

The drawing numbers and revisions
Part Information
Test results
Material declarations numbers
Any deviations from earlier elements

Key Steps in PPAP

The PPAP process involves several key steps. These steps include:

Submission of documents: The manufacturer submits documents, including the design record, engineering change documents, and production process documents.
Design FMEA: The manufacturer conducts a Design Failure Mode and Effects Analysis (FMEA) to identify potential design problems.
Prototype: The manufacturer produces a prototype of the product.
Process FMEA: The manufacturer conducts a Process Failure Mode and Effects Analysis (FMEA) to identify potential process problems.
Production part approval: The manufacturer produces the parts, and the customer approves them.
Part submission warrant: The manufacturer submits a Part Submission Warrant (PSW) to the customer.
Sample product: The manufacturer produces sample products for the customer to approve.
Production: The manufacturer produces the products according to the approved production process.

Conclusion

The Production Part Approval Process (PPAP) is a crucial quality control procedure that helps ensure that a manufacturer’s production process can consistently produce products that meet customers’ specifications. By identifying potential problems early in the production process, manufacturers can reduce costs, improve customer satisfaction, and ensure that customers receive products that meet their specifications.

FAQs

Q. What is PPAP?
A. PPAP is a standardized process in the automotive industry but is also widely used in other industries. The PPAP process is a quality control process that helps manufacturers ensure that their production process can consistently produce products that meet customers’ specifications.
Q. What is the purpose of PPAP?
A. The primary purpose of PPAP is to ensure that customers receive products that meet their specifications. PPAP is an essential tool that helps manufacturers identify and eliminate potential problems early in production, reducing the risk of product failure or customer complaints.
Q. What are the benefits of PPAP?
A. The benefits of implementing PPAP in production include early problem identification, cost reduction, and improved customer satisfaction.
Q. What are the key steps in PPAP?
A. The key steps in PPAP include submission of documents, design FMEA, prototype, process FMEA, production part approval, part submission warrant, sample product, and production.
Q. Is PPAP only used in the automotive industry?
A. While PPAP is a standardized process in the automotive industry, it is also widely used in other industries, including aerospace, medical devices, and electronics.
Q. Who is responsible for conducting the PPAP process?
A. The manufacturer is responsible for conducting the PPAP process and submitting the necessary documents and samples to the customer for approval.
Q. What happens if a problem is identified during the PPAP process?
A. If a problem is identified during the PPAP process, the manufacturer must take corrective action to address the issue and resubmit the necessary documents and samples to the customer for approval.
Q. How long does the PPAP process typically take?
A. The length of the PPAP process can vary depending on the complexity of the product and the number of potential problems identified. However, the process typically takes several weeks to complete.
Q. Can PPAP be used for existing products?
A. PPAP is typically used for new products but can also be used for existing products if changes are made to the production process or product design.