The Production Part Approval Process (PPAP) is used in the automotive supply chain to establish confidence in component suppliers and their production processes, by demonstrating that all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.

The Production Part Approval Process (PPAP) provides customers with evidence that: a) Component suppliers have understood their requirements; b) The product meets the customers requirements; c) The production process is capable of consistently producing conforming product. The The PPAP process is currently governed by the PPAP manual published by the Automotive Industry Action Group (AIAG).

The PPAP requires the manufacture of a sample number of parts on actual production tooling, using the same procedures, personnel, production facility, and all other aspects of the expected production run. This sampling is of some finite number, usually something like 300 pieces. These are then analyzed in several ways to ensure the production run meets all of the requirements the customer requests. Doing a PPAP is not just a task in paperwork only useful for the customer, but rather a valuable tool usable by the supplier to help identify possible trouble spots in the production ahead.

The PPAP manual is the ultimate resource for those in automotive supplier quality management. The manual contains the PPAP checklist which includes all the requirements, called elements, for a complete PPAP package. The checklists identify different PPAP levels (from 1 to 5). There are 18 possible elements that must be checked off. Each PPAP level determines the specific requirements for each element and indicates which elements should be submitted to the customer. The PPAP Elements give the supplier a chance to formally think through how they can handle future problems that may arise in production, and give supervisors and managers a simple road map to follow to perform their production tasks. The 18 elements or documents that comprise the PPAP are:

1. Design Records
A copy of the drawing. If the customer is responsible for designing, this is a copy of customer drawing that is sent together with the Purchase Order (PO). If supplier is responsible for designing this is a released drawing in supplier’s release system.
2. Authorized Engineering Change Documents
A document that shows the detailed description of the change. Usually this document is called “Engineering Change Notice”, but it may be covered by the customer PO or any other engineering authorization.
3. Customer Engineering Approval, if required
This approval is usually the Engineering trial with production parts performed at the customer plant. A “temporary deviation” usually is required to send parts to customer before PPAP. Customer may require other “Engineering Approvals”.
4. Design Failure Modes and Effects Analysis (DFMEA), applied in special situations
A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed-off by supplier and customer.
5. Process Flow Diagram
A copy of the Process Flow, indicating all steps and sequence in the fabrication process, including incoming components.
6. Process Failure Modes and Effects Analysis (PFMEA)
A copy of the Process Failure Mode and Effect Analyis (PFMEA), reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and indicate “what could go wrong” during the fabrication and assembly of each component.
7. Control Plan
A copy of the Control Plan, reviewed and signed-off by supplier and customer. The Control Plan follows the PFMEA steps, and provides more details on how the “potential issues” are checked in the incoming quality, assembly process or during inspections of finished products.
8. Measurement System Analysis (MSA)
MSA usually contains the Gage R&R for the critical or high impact characteristics, and a confirmation that gauges used to measure these characteristics are calibrated.
9. Dimensional Results
A list of every dimension noted on the ballooned drawing. This list shows the product characteristic, specification, the measurement results and the assessment showing if this dimension is “ok” or “not ok”. Usually a minimum of 6 pieces is reported per product/process combination.
10. Records of Material / Performance Test Results
A summary of every test performed on the part. This summary is usually on a form of DVP&R (Design Verification Plan and Report), which lists each individual test, when it was performed, the specification, results and the assessment pass/fail. If there is an Engineering Specification, usually it is noted on the print. The DVP&R shall be reviewed and signed off by both customer and supplier engineering groups. The quality engineer will look for a customer signature on this document. In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print. The material certification shall show compliance to the specific call on the print.
11. Initial Process Studies
Usually this section shows all Statistical Process Control charts affecting the most critical characteristics. The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value.
12. Qualified Laboratory Documentation
Copy of all laboratory certifications of the laboratories that performed the tests reported on section 10.
13. Appearance Approval Report (AAR)
A copy of the AAI (Appearance Approval Inspection) form signed by the customer. Applicable for components affecting appearance only.
14. Sample Production Parts
A sample from the same lot of initial production run. The PPAP package usually shows a picture of the sample and where it is kept (customer or supplier).
15. Master Sample
A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections.
16. Checking Aids
When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including dimensional report of the tool.
17. Customer-Specific Requirements
Each customer may have specific requirements to be included on the PPAP package. North America auto makers OEM (Original Equipment Manufacturer) requirements are listed on the IATF website.
18. Part Submission Warrant (PSW)
This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for “results meeting all drawing and specification requirements: yes/no” refers to the whole package.

PPAP requirements are typically distinguished by level as follows:

  • Level 1 – Part Submission Warrant (PSW) only submitted to the customer.
  • Level 2 – PSW with product samples and limited supporting data.
  • Level 3 – PSW with product samples and complete supporting data.
  • Level 4 – PSW and other requirements as defined by the customer.
  • Level 5 – PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location.

Hebei Shida Seal Group is located in Qinghe, Hebei, China, and is a Tier I supplier of vehicle sealing system and molded rubber products to the automotive industry, and has attained TS 16949 designation. Main products are automotive body mounted seals & weatherstrips extruded from EPDM,PVC and TPV which can be reinforced with steel or steel wire carriers and wiring harness rubber gromemts, air intake hoses, brake pedal pads and related molded rubber products.

Hebei Shida Seal Group Co., Ltd. can currently provide every level of PPAP. Our most commonly requested PPAP’s is Level 3 PPAP (PSW with product samples and complete supporting data.). We have been supplying Automotive Level 3 PPAP documentation and production parts for large volume automotive use for over 10 years.