What's Production Part Approval Process (PPAP) and What specific challenges does Elements of PPAP address?

Abstract

PPAP, which stands for Production Part Approval Process, is a process that manufacturers follow to ensure that the parts they produce are according to customer specifications and of the highest quality. PPAP allows suppliers to provide evidence of their processes in place that ensure their ability to produce parts that consistently meet customer specifications.

PPAP is Essential in automotive and aerospace industries. The manufacturers must accomplish these seven documents for PPAP:

• Product description
• Samples of the part
• Manufacturing process
• Inspection process
• Quality plan
• Part history
• Supplier approval form

It is essential to have a good understanding of PPAP and how to perform it to help ensure smooth production and timely delivery of your products.

The purpose of PPAP is to make sure that parts are manufactured according to the customer’s specifications and that they meet the customer’s requirements. PPAP also helps to ensure that suppliers are capable of producing quality parts consistently and be able to make adjustments to the product as needed by the customer.

Keywords

Production Part Approval Process (PPAP), Suppliers,  Customers, Measurement, Approval Processes, Quality Parts 

Learning Outcomes

After undergoing this article you will be able to understand the following:

1. What's exactly PPAP?

2. What's the purpose of PPAP?

3. What specific challenge(s) does this address?

4. What are the benefits of PPAP?

5. What is IMDS in PPAP?

6. What are Elements of PPAP?

7. Conclusions

8. FAQs

References 

1. What's exactly PPAP?

The Production Part Approval Process (PPAP) handbook is an industry standard that outlines the process to demonstrate engineering design and product specifications are met by the supplier’s manufacturing process. Through PPAP, suppliers and customers agree upon the requirements needed to obtain approval of supplier manufactured parts. Applicable to all parts and commodities, PPAP principles help reduce delays and non-conformances during part approval by providing a consistent approval process.

2. What specific challenge(s) does this address?

• Provides understanding of information required to obtain part approval and standardizes the part approval process
• How to obtain approval of parts/processes after part design changes and/or process changes
• Ensures part submissions are submitted with proper information and enough data to sustain product conformance
• Provides a record of part conformance at launch (allows for measurement of drift from origin)
• Details pertinent design records to ensure traceability of part design status at origin
• Controls product and process change process, providing an approval outlet for all changes to ensure conformance to the next level assembly/process

3. What are the benefits of PPAP?

• Consistent part approval process
• Assurance parts conform to customer requirements
• Evidence of process stability
• Controls product and process change process, providing an approval outlet for all changes to ensure conformance to the next level assembly/process

4. What is IMDS in PPAP?

IMDS aids the customer in the supply network to verify the contents of their purchased parts before and during the part approval process. The Production Part Approval Process (PPAP) requires IMDS submission for each part number before PPAP approval can be granted to the supplier.

5. What are Elements of PPAP?

List of PPAP Elements

1. Design Records
2. Authorized Engineering Change Documents
3. Engineering Approval
4. Design Failure Mode and Effects Analysis (DFMEA)
5. Process Flow Diagrams
6. Process Failure Mode and Effects Analysis (PFMEA)
7. Control plan
8. Measurement System Analysis Studies (MSA)
9. Dimensional Results
10. Records of Material / Performance Tests
11. Initial Sample Inspection Report
12. Initial Process Studies
13. Qualified Laboratory Documentation
14. Appearance Approval Report (AAR)
15. Sample Product Parts
16. Master Sample
17. Checking Aids
18. Customer-Specific Requirements
19. Part Submission Warrant (PSW)

Find below the brief of all elements:

1. Design Documentation
   • Design documentation shall include both a copy of the customer and the supplier’s drawings. The documentation should also include a copy of the purchase order. In some cases the supplier is required to supply documentation of material composition.
     • The purchase order is used to confirm that the correct part is being ordered and that it is at the correct revision level.
     • The design engineer is responsible for verifying that the two drawings match and all critical or key characteristics have been identified.
     • Material composition information is required to supply evidence that the material used manufacture the parts meets the customer’s specific requirements.

2. Engineering Change Documentation
   • If the PPAP is being required due to a request for a change to a part or product, the documentation requesting and approving the change must be included in the PPAP package. This documentation usually consists of a copy of the Engineering Change Notice (ECN), which must be approved by the customer engineering department.
3. Customer Engineering Approval
   • When required as part of the PPAP, the supplier must provide evidence of approval by the customer engineering department.
     • If required, pre-PPAP samples are ordered by the customer for onsite testing. The samples must be production intent and ship with a waiver so that testing can be done. When testing is complete, the test engineers will provide an approval form for inclusion in the PPAP submission.
     • Note: A copy of a “Temporary Deviation” is normally required to submit parts to the customer prior to a PPAP approval.

4. Design Failure Mode and Effects Analysis
   • Design Failure Mode and Effects Analysis (DFMEA) is a cross-functional activity that examines design risk by exploring the possible failure modes and their effects on the product or customer and their probability to occur. These failure modes can include:
     • Product malfunctions
     • Reduced performance or product life
     • Safety and Regulatory issues
   • The DFMEA is a living document that should be reviewed and updated throughout the product life cycle.
5. Process Flow Diagram
   • The Process Flow Diagram outlines the entire process for assembling the component or final assembly in a graphical manner. The process flow includes incoming material, assembly, test, rework and shipping.
6. Process Failure Mode and Effects Analysis
   • Process Failure Mode and Effects Analysis (PFMEA) reviews all of the steps in the production process to identify any potential process quality risk and then document the applied controls. The PFMEA is also a living document and should be updated even after the product is in normal production.
7. Control Plan
   • The Control Plan is an output from the PFMEA. The Control Plan lists all product Special Characteristics and inspection methods required to deliver products that continually meet the customer quality requirements.
8. Measurement System Analysis Studies
   • Measurement System Analysis (MSA) studies will include Gage Repeatability & Reproducibility (GR&R) studies on measurement equipment used during assembly or quality control checks. Calibration records for all gages and measurement equipment must be included.
9. Dimensional Results
   • Dimensional layout of sample parts is required to validate the product meets the print specifications. The samples should be randomly selected from a significant production run usually at least 30 pieces. Each dimension on the drawing is measured on the final assembly to make sure that it falls within specification. The results are recorded in a spreadsheet and included within the PPAP submission.
10. Records of Material / Performance Tests
    • This element should contain a copy of the Design Verification Plan and Report (DVP&R). The DVP&R is a summary of every validation test performed on the part. It should list each and every test performed, a description of how the test was performed, and the results of each test.
    • This section may also include copies of all the certification documents for all materials (steel, plastics, etc.) listed on the prints. The material certification shall show compliance to the specific call on the print.
11. Initial Process Studies
    • Initial process studies will be done on all the production processes and will include Statistical Process Control (SPC) charts on the critical characteristics of the product. These studies demonstrate that the critical processes are stable, demonstrate normal variation and are running near the intended nominal value.
12. Qualified Laboratory Documentation
    • Qualified laboratory documentation consists of the industry certifications for any lab that was involved in completing validation testing. This could be for an in-house test lab or any offsite contracted test facilities that were used for validation or material certification testing.
13. Appearance Approval Report
    • The Appearance Approval Inspection (AAI) is applicable for components affecting appearance only. This report verifies that the customer has inspected the final product and it meets all the required appearance specifications for the design. The appearance requirements could include information regarding the color, textures, etc.
14. Sample Production Parts
    • Sample production parts are sent to the customer for approval and are typically stored at either the customer or supplier’s site after the product development is complete. A picture of the production parts is usually included in the PPAP documentation along with documentation regarding the location that the parts are being stored.
15. Master Sample
    • A master sample is a final sample of the product that is inspected and signed off by the customer. The master sample part is used to train operators and serves as a benchmark for comparison to standard production parts if any part quality questions arise.
16. Checking Aids
    • This is a detailed list of checking aids used by production. It should include all tools used to inspect, test or measure parts during the assembly process. The list should describe the tool and have the calibration schedule for the tool. Checking aids may include check fixtures, contour, variable and attribute gages, models or templates.
    • MSA may be required for all checking aids based on customer requirements.
17. Customer Specific Requirements
    • This element of the submission package is where any special customer requirements are contained. For bulk materials, the customer specific requirements shall be recorded on the “Bulk Material Requirements Checklist”.
18. Part Submission Warrant
    • The Part Submission Warrant (PSW) form is a summary of the entire PPAP submission. A PSW is required for each of part number unless otherwise stated by the customer. The PSW includes:
      • The reason for submission (design change, annual re-validation, etc.)
      • The level of documents submitted to the customer
      • Declaration of part conformity to customer requirements
      • A section provided for any required explanation or comments
      • Supplier authorized person signature along with contact information
      • An area for the customer to indicate disposition of the PPAP

The PPAP process is a detailed and lengthy process. The PPAP package includes documentation of various multiple cross-functional tools and documents the ability of the supplier to meet all customer requirements. PPAP provides customers adequate information to validate that all areas of the design and production processes have been reviewed thoroughly to ensure that only high quality products will be allowed to ship to the end customer.

7. Conclusions

The PPAP is a vital first step in establishing a sound and reliable relationship with a supplier. It allows both parties to set the groundwork for what is expected in the partnership. A supplier who can complete the PPAP is much more likely to meet the quality requirements for the critical components. These components, the bearings, bushings, assemblies, etc. must all be of highest quality to ensure that friends and families can travel safely in their vehicles.

8. FAQs

Q. Is APQP the same as PPAP?

Ans : 

PPAP is an output of APQP, showing if a supplier can consistently manufacture parts in accordance with the customer's expectations. Both PPAP and APQP are not equivalent though - they have different functions: while APQP verifies that processes will produce consistent outcomes to meet standards, PPAP validates that those results were achieved.

Q. Which comes first APQP or PPAP?

Ans : 

Advanced Product Quality Planning (APQP) is the overarching framework to managing product and process design. There are phases of APQP, and the Product Part Approval Process (PPAP) is triggered in Phase 4.

Q. How is APQP related to PPAP?

Ans :

The process of APQP helps ensure that customer requirements are met when both designing and producing goods. The fourth phase involving PPAP (Production Part Approval Process) deliverables, tests a supplier's ability to consistently manufacture parts which live up to the customers standards. It is essential for any product development cycle in order to guarantee satisfactory delivery from the supplier and total satisfaction on behalf of their customer.

Q. What is the PPAP phase in APQP?

Ans :

The Production Part Approval Process (PPAP) of the Product & Process Validation Phase, also known as Phase 4 in APQP, is integral to minimizing risk by ensuring effective change control. This stage validates both parts and processes that go into manufacturing a product, thus affirming its quality. Through PPAP's part approval process, all potential issues can be addressed before entering production mode.

References 

https://en.m.wikipedia.org/wiki/Production_part_approval_process

Webmaster, AIAG. "(APQP) Advanced Product Quality Planning | AIAG". www.aiag.org. Retrieved 18 August 2022.

 Webmaster, AIAG. "(PPAP) Production Part Approval Process | AIAG". www.aiag.org. Retrieved 4 July 2022.

 "PPAP Guide (Production Part Approval Process)". PPAP Guide. 2013. Retrieved 27 June 2013.

 Webmaster, AIAG. "(PPAP v4) Production Part Approval Process Manual Version 4 | AIAG". www.aiag.org. Retrieved 18 August 2022.

 "PPAP (Production Part Approval Process)". Kelly's Tech Library. 2012. Retrieved 15 December 2012.

 "Design Records | PPAP Documents". www.ppapdocuments.com. Retrieved 14 August 2018.