Seminar PPAP

8/8/2019 Seminar PPAP

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1. INTRODUCTION

The Production Part Approval Process (PPAP) is used in the automotive supplychain 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."

PPAP is an important part of the product development process, allowing producers to

evaluate the components and sub-systems which they receive from suppliers, and

establishing confidence in the supplier's management systems. Although individual

manufacturers have their own particular requirements.

PPAP was the culmination of joint efforts by Chrysler, Ford and GM, working

under the auspices of the Automotive Industry Action Group(AIAG) and the American

Society for Quality Control (ASQC), to develop industry-wide standards that would

apply to all their many suppliers. The first manual spelling out the multiple requirement

of PPAP was published in 1993. PPAP is part of the auto industry's overall Advance

Product Quality Planning initiative, step-by-step procedures designed to ensure

production of an end-product that will satisfy consumers

2. Who Uses Production Part Approval Process?

The auto industry giants like Ford, Chrysler, GM and their vast network of

suppliers (partners in AIAG, Auto Industry Action Group) strictly adhere to the PPAP.

In their industry, a suppliers cannot ship components until the PPAP approval, or

someone composes a written deviation to allow shipment prior to approval (much like

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our TD process). Several semiconductor companies such as Freescale are also reportedly

using PPAP

3. Purpose of Production Part Approval Process

The purpose of the Production Part Approval Process (PPAP) is:

To provide the evidence that all customer engineering design record and

specification requirements are properly understood and fulfilled by the manufacturing

organization.

To demonstrate that the now established manufacturing process has the potential

to produce product that consistently meets all requirements during an actual

production run at the quoted production rate

4. When Production Part Approval Process Submission Required?

In general a PPAP is required anytime a new part or a change to an existing part

or process is being planned. It is at the discretion of each Industries Division to determine

when and if a PPAP submission will be required. As a supplier you should have the type

of quality system that develops all of the requirements of a PPAP submission regardless

of whether you have been asked to deliver a submission. In the event a PPAP submission

is not requested, quality reserves the right to request any of these documents at any time

during the life of the product. Quality reserves the right to request a PPAP submission for

a variety of reasons including all of the following.

New parts, process or suppliers:

1. New part or product



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2. New supplier

3. New process or technology

Changes to existing product:

1. Change to construction, material, or component

2. New, additional or modified tools

3. Upgrade or re-arrangement of existing tools

4. Tooling, production, or equipment transferred to a different site

5. Change of supplier or non-equivalent materials/services

6. Product when tooling has been inactive for 12 months

7. Product or process changes on the components of the product

8. Change in test or inspection method

9. Bulk material: New source of raw material

10. Change in product appearance attributes

11. Change in production process or method

12. Change of sub-supplier or material source

5. Critical Elements of the Process Approach

Process owner exists

Process is defined

Process is documented

Linkages of process established

Process monitored, analyzed and improved

Records maintained

6. Approval of Production Part Approval Process

The result of the PPAP process is a series of documents gathered in one specific

location (a binder or electronically) called the "PPAP Package". The PPAP package is a

series of documents which need a formal approval by the supplier and customer. The

form that summarizes this package is called PSW (Part Submission Warrant). The



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approval of the PSW indicates that the supplier responsible person (usually the Quality

Engineer) has reviewed this package and that the customer has not identified any issues

that would prevent its approbation.

The documentation on the PPAP package is closely related to the Advanced Product

Quality Planning process (APQP) used during the design and development of new

vehicles and component systems to reduce the risk of unexpected failure due to errors in

design and manufacture. The PPAP manual is published by, Industries and specifies

generic requirements for obtaining PPAP approvals. Additional customer specific

requirements may be imposed by particular clients (vehicle manufacturers) and

incorporated in the purchasing contracts. Suppliers are required to obtain PPAP approval

from the vehicle manufacturers whenever a new or modified component is introduced to

production, or the manufacturing process is changed. Obtaining approval requires the

supplier to provide sample parts and documentary evidence showing that:

1) The clients requirements have been understood

2) The product supplied meets those requirements

3) The process (including sub suppliers) is capable of producing conforming product

4) The production control plan and quality management system will prevent non-

conforming product reaching the client or compromising the safety and reliability of

finished vehicles

Production Part Approval Process (PPAP) may be required for all components and

materials incorporated in the finished product, and may also be required if components

are processed by external sub-contractors.

7. Elements Of Production Part Approval Process

PPAP specifies steps and standards for every phase of the planning and production

process. PPAP documentation, which follows the product from inception to completion,contains at least 18 separate elements by the time production is completed. These

include design records, engineering approvals (including approval of any changes made

during the production phase), process-flow diagram, failure modes and effects analysis

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(in both design and process phases), measurement system analysis studies and all

product test results.

7.1. Design Records

fig 1 Drawing Sheet

A copy of the drawing. If the customer is design responsible this is a copy of

customer drawing that is sent together with the Purchase Order (PO). If supplier is design

responsible this is a released drawing in supplier's release system. Hard copies of the

following items are to be submitted with the PPAP package: Engineering Drawings

Process, Material and Engineering Specifications

Design Records are required for all components and details e.g. where the part is a

machined casting; the machining supplier is responsible to produce the design records for



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the casting, which includes the Suppliers approved Part Submission Warrants and all

Design Records for all sub-supplier parts.

Where the design record is in electronic format, the supplier shall still provide ahard

copy of those documents.

7.2. Authorized Engineering Change (Note) Documents

It is possible that during product development a change is suggested in the

product, part or tooling by R&D / Engineering but not yet incorporated in the drawing /

standard. If such changes are incorporated in the part / product submitted for Production

Part Approval, the authorized engineering change documents must also be submitted .

This document 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. PPAPs are NOT to be submitted if the design

requirements have not been met

7.3. Engineering Approval

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". As an example

included in this document.

7.4. DFMEA (Design Failure Mode and Effect Analysis)

A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and

signed-off by supplier and customer. If customer is design responsible, usually customer

may not share this document with the supplier. However, the list of all critical or high

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impact product characteristics should be shared with the supplier, so they can be

addressed on the PFMEA and Control Plan.

7.5. Process Flow Diagram

A copy of the Process Flow, indicating all steps and sequence in the fabrication

process, including incoming components. The production process steps and the sequence

should be clearly described, as appropriate. Process Flow Chart should project a pictorial

representation of the entire manufacturing process.

Typically it should start with incoming material inspection to packing and pre-

dispatch inspection. All operations should be represented by appropriate symbols. Details

of Product & Process Characteristics to be filled-up in the format along with its

Characteristic Classification.

Fig 2 Process flow diagram


Rawgoods

received

Rawgood

warehous

Manufacturing Process

Non

confirming

product flow

Rework

Scrap Inspection Testing

Finishedgood

warehousing

To market
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7.6. PFMEA (Process Failure Mode and Effect Analysis)

A copy of the Process Failure Mode and Effect Analysis (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.

Process Failure Mode & Effects Analysis (PFMEA) is carried out to analyse a

process for potential failure mode and its effects. PFMEA should be carried out by a

Cross-Functional Team approach. Actions on prioritized failure modes must be

completed and the revised rating should be documented. The completed PFMEA

document should be submitted along with the PSW. While preparing PFMEA, the focus

should be on Process deficiencies, rather than on Design related deficiencies.

7.7. 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.

7.8. Measurement System Analysis Studies (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. Measurement system Analysis studies such as Gage R&R, Bias, and Linearity

& Stability shall be carried out for all equipments used for new or modified gages,

measurement, and test equipments.

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Gauge Capability study should be performed for all new gauges procured & their

capability indices reviewed before use. PU /Area must carryout Accuracy, Bias and

Linearity studies for all used and new equipment, new or modified gages, measuring

tools and test equipment.

In addition, Gauge Repeatability & Reproducibility (GRR) studies should be

carried out for equipments that are used for measuring critical and significant

characteristics. It is recommended to conduct stability studies of these equipments and

monitor there on. For attribute characteristics such as finish, feel, dent, rundown etc.,

attribute MSA is to be carried out as per MQS guideline. MSA Attribute study to be

conducted on attribute defects & not on attribute measuring equipment.

7.9. Dimensional Results

fig. 3 Dimensional tolerances example

A list of every dimension noted on the ballooned drawing. This list shows the

product characteristic, specification, the measurement results and the assessment showing



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if this dimension is "ok" or "not ok". Usually a minimum of 6 pieces is reported per

product/process combination.

7.10. Records of Material / Performance Tests

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.

7.11. 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.

The purpose of conducting initial process capability study is to determine if the

production process is capable / potential to produce products that meet internal / external

customer requirements and result in customer satisfaction. For all Significant and Critical

characteristics, (SCs & CCs) the concerned should be stable and under statistical control

with Preliminary Process Capability Index (Ppk) above 1.67 in Production Trial Run and

on-going process capability index (Cpk) greater than 1.33 in regular production.

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The purpose of process capability study is to determine whether the production

process has the potential to produce products that will meet the customer requirements

and result in customer satisfaction. The Ppk study should be based on 100 (minimum 50)

consecutively produced parts when process is in statistically stable condition where only

Common Causes of variation are present. The performance index (Ppk) should be above

1.67.It is essential to conduct Normality study to determine whether the process data are

normally distributed. This is evident by calculating Skewness & Kurtosis. Skewness is

the measure of Symmetry of the distribution & Kurtosis the measure of peakness of the

distribution.

Tests for Normality include Anderson Darling test, Ryan Joiner test,

Kolmogorov Smirnov test. MQS recommends the use of Minitab software for

conducting these tests. The skewness & Kurtosis should be within acceptable limits to

proceed further for Process capability calculations.

7.12. Qualified Laboratory

The supplier shall have Inspection and Testing for PPAP (as well as regular production)

performed by a qualified laboratory as defined by customer

requirements.

The suppliers qualified laboratory (internal or external) shall have a laboratory

scope and documentation showing that the laboratory is qualified for the type of

measurements or tests being conducted.

Supplier shall submit test results on the laboratory letterhead or the normal

laboratory report format when an outside laboratory is used. The following

information must be included on the report:

Name of the laboratory that performed the tests.

The date(s) of the tests.

The standard(s) used to run the tests shall be identified.



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7.13. Appearance Approval Report

A copy of the AAI (Appearance Approval Inspection) form signed by the

customer. Applicable for components affecting appearance only. Appearance Approval

Report applies for parts with colour, grain, surface finish and texture requirements that

are visible to the customer. It is recommended to take a photograph of the item,

preferably by a digital camera with good resolution and submit the photographs along

with the PPAP submissions.

7.14. Sample Production Parts

Fig 4 can ban tag

A sample from the same lot of initial production runs. The PPAP package usuallyshows a picture of the sample and where it is kept (customer or supplier).Unless

otherwise specified by the using plant approval activity, the supplier shall submit 3

samples with the PPAP. If production parts will be produced from more than one cavity,

mold, tool, die, pattern, or production process, e.g. line or cell, then the supplier shall



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submit one sample for each position of a multiple cavity die, mold, tool or pattern, or

production process. Such samples shall be

appropriately identified.

7.15. Master Sample

A sample signed off by customer and supplier, that usually is used to train

operators on subjective inspections such as visual or for noise. If production parts will be

produced from more than one cavity, mold, tool, die, pattern, or production process, e.g.

line or cell, then the supplier shall retain one sample for each position of a multiple cavity

die, mold, tool or pattern, or production process.

7.16. 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. Checking aid list

includes all fixtures, gauges, models and templates specific to the product for which

PPAP is carried out. The same should be submitted along with PSW. If requested by the

approval authority, checking aids are to be reviewed for a specific component or

assembly.

PU / Area should certify that all aspects of the checking aids are in agreement

with part dimensional requirements. PU / Area must have drawings for all checking aids,

other than the standard instruments. The PU / Area shall document all released

engineering design changes that have been incorporated in the checking aids at the time

of submission. Generic checking aid list, if available is to be referenced in PSW format.



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7.17. Customer Specific Requirements

Each customer may have specific requirements to be included on the PPAP

package. It is a good practice to ask the customer for PPAP expectations before even

quoting for a job.

7.18. 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. If there is any

deviations the supplier should note on the warrant or inform that PPAP cannot be

submission.

The purpose of thePart Submission Warrant(PSW) is to document

thesubmission and the approval or rejection of purchased parts prior to production.

7.18. A Submission Levels

Submission levels define which elements are required to be submitted. The levels

are used for different reasons and applications. The level to be submitted is determined

by Industry, and unless otherwise noted, always defaults to Level 3 which is a full PAP

submission. There are five submission levels listed below, and each is typically applied to

the specific areas listed.

Level 1 - Warrant only and Appearance Approval Report as requested



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submitted to the customer. Applied to: Non-critical parts, non critical raw/bulk

material or catalog/ commodity parts for electrical applications and re-certification of

existing parts previously approved. Also used for self-certification.

Level 2 - Warrant with product samples and limited supporting data

submitted to the customer. Applied to: Critical Bulk products such as

Plastic/Paint/Chemicals, critical fasteners, simple material changes, simple revision level

only changes or simple print updates not affecting form-fit-function. This level can also

be applied to low and medium risk

parts within a product family.

Level 3 - Warrant with product samples and complete supporting data

submitted to customer. Default Cooper Industries Submission

Level Applied to: New parts on programs, changes affecting. Form-fit-function,

reliability, or performance. All products resourced to new suppliers, serial production

parts, and existing high risk parts undergoing a part number change.

Level 4 - Warrant and other requirements as defined by the customer. This level is

reserved for special applications only. Applied to: This level can only be applied with

prior approval from the designated divisional quality PPAP representative.

Level 5 - Warrant with product samples and complete supporting data reviewed at

the suppliers manufacturing location. Applied to: On site review as requested by each

Division.

8. Benefits of Production Part Approval Process

Many benefits exist for both customers and suppliers by adopting PPAP such as:

1. Clearly planned, justified, validated, documented, and communicated (including

training) key manufacturing process functions.

2. Clearly communicated design requirements and design gaps.



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3. Improved quality over product life cycle.

4. Inclusion of customer consent in the change process for better visibility (and

Copy Exact requirements where implemented).

5. Quick resolution of new problems due to documented product history

6. Improved customer/supplier relationships

7. Optimized business output and profits

8. Developing a packet of documents used to assure that all reasonable risks have

been addressed.



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REFERENCES

: Reference to a book:

[1] Serope Kalpakjian, Stephen R. Schmid, and Chih-Wah Kok , Manufacturing

Processes for Engineering Materials Vol. I. 2nd edition, New York: Wiley Publications,

1999.

[2] Dominic Reeve, Andrew Chadwick, and Christopher Fleming, Coastal

Engineering: Processes, Theory and Design Practice Johnson Publication, 1988.

: Reference to a website

[3] http://www.asqsandiego.net

[4] http://www.anixter.com

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http://www.amazon.co.uk/Coastal-Engineering-Processes-Theory-Practice/dp/0415583535/ref=sr_1_2?s=books&ie=UTF8&qid=1294647243&sr=1-2http://www.amazon.co.uk/Coastal-Engineering-Processes-Theory-Practice/dp/0415583535/ref=sr_1_2?s=books&ie=UTF8&qid=1294647243&sr=1-2http://www.asqsandiego.net/http://www.anixter.com/http://www.amazon.co.uk/Coastal-Engineering-Processes-Theory-Practice/dp/0415583535/ref=sr_1_2?s=books&ie=UTF8&qid=1294647243&sr=1-2http://www.amazon.co.uk/Coastal-Engineering-Processes-Theory-Practice/dp/0415583535/ref=sr_1_2?s=books&ie=UTF8&qid=1294647243&sr=1-2http://www.asqsandiego.net/http://www.anixter.com/