Faculty Credentials:

 B.Tech (Mechanical)

 Honored by IIT Guwahati for Techniche Representative in Year 2011

 Certified ‘Internal Auditor for Quality Management System i.e. ISO

9001 : 2015 & IATF 16949 : 2016’.
 Certified ‘Internal Auditor for EHS Standards i.e. ISO 14001 : 2015,
OHSAS 18001 :2007 & ISO 45001 : 2018.
 Certified for NPD related documents (APQP, PPAP & FMEA).

 Certified for Auto Cad 2012.

Jaideep Gupta  7+ Years of Experience in Automobile Industry (QC,QA & QMS).

PPAP : NEED, REQUIREMENT, 19 DOCUMENTS, LEVELS AND SUBMISSION

© Copyright by Industrial training by Jaideep Gupta (ITJ).
All rights reserved. No any part of this training material is allowed for reproduced in any form or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior written permission.

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PPAP - Training Index
PRODUCTION PART APPROVAL PROCESS (PPAP)
 Needs of PPAP

PPAP
 Submission of PPAP
 Requirements of PPAP
 PPAP Documents (19 Nos.)
 PPAP Submission Level
 PPAP Submission Status

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Needs of PPAP

Why PPAP……………?

It is to determine

 Is the Supplier has understood all Customer Engineering Design

Records and Specification Requirement (Including Safety & Regulatory
requirement) ?

 Is the Supplier’s process has the potential to produce product

consistently meeting these requirements during an actual run at the
quoted production run ?

PPAP : Production Part Approval Process

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Submission of PPAP

When PPAP…………?
 A New part or Product (i.e. A specific part, Material or Color not
previously supplied to the specific customer).

 Correction of discrepancy on a previously submitted part.

 Product modified by an Engineering change to design records,

specifications, or materials.

Customer can waive PPAP requirements for an item, however the

documented evidence of waiver is required.

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PPAP Requirements

Significant Production Run

 Take Product for PPAP from a Significant Production Run.

 Production run is from One hour to Eight hour production with a

minimum 300 Consecutive lot, unless other specified by the authorized
Customer representative

 The run shall be manufactured at the Production site using tooling,

Gauging, Materials and operators from the Production Environment.

 Parts from each production process be measured and representative

parts tested.

 Submitted Sample to be taken in manner to assure that it represents

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‘Steady state’ operation of process.
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PPAP Documents (19 Nos)
1. Design Record:

• If supplier is design responsible, this is a released drawing in supplier's

release system.

• But If the customer is design responsible, this is a copy of customer

drawing that is sent together with the Purchase Order (PO).

• When Design Record in Electronic Format (i.e. CAD/CAM, CATIA etc.),

Produce a Hard Copy to identify the measurement taken.

2. Authorized Engineering Change (note) Documents:

• Usually this document is called "Engineering Change Notice’’.

• A document that shows the detailed description of the change.

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PPAP Documents (19 Nos)
3. Customer Engineering Approval:

• This approval is usually for the Engineering trial with production parts
performed at the customer plant.

• Any deviation approval from Customer i.e. “Temporary / Permanent

deviation approval" .

4. DFMEA:

• 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.
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PPAP Documents (19 Nos)
5. Process Flow Diagram:

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

process,

• Commonly, It starts from Receiving and ends at Shipping .

6. PFMEA:

• A copy of the Process Failure Mode and Effect Analysis (DFMEA),

reviewed and signed-off by supplier and customer.

• The PFMEA follows the sequence from Process flow diagram, and
indicate "what could go wrong" during the fabrication and assembly of
each component.
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PPAP Documents (19 Nos)
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.

• It defines all the methods used for Product & Process Control and complies
with Customer Specific Requirement.

8. Measurement System Analysis Studies (MSA) :

• It contains the Gauge R&R, Linearity, Bias etc. for all new or modified Gauge,
Measurement & Test Equipment .
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PPAP Documents (19 Nos)
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".

• In Case of Multi Cavity Mold, The Supplier shall submit dimensional result
for all cavities.

10. Material / Performance Test Result :

• Perform test for all part(s) and material(s) when chemical, physical or
metallurgical requirements specified in Control Plan.

• Test report includes supplier name, supplier Code (If any), date of
testing, number of part tested, result of testing etc.
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PPAP Documents (19 Nos)
11. Initial Process Studies:

• Before submission of PPAP, Process Capability / Performance result must

meet the customer requirements for all ‘Special Characteristics’.

• Shall obtain customer concurrence on the index for estimating initial

process capability prior to submission’. As per AIAG,
Index Value › 1.67 : Process currently meet Customer Complaint
1.33 ‹ Index Value ‹ 1.67 : Process is currently acceptable but needs Improvements
Index Value ‹ 1.33 : Process not meet acceptance criteria.

• If Acceptance criteria not met, then inform to customer and provide 100 %
inspection to that characteristics

Note :- Where no special characteristic are identified, Customer reserves the

right
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to demonstrate Initial Process Capability on other characteristics.
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PPAP Documents (19 Nos)
12. Qualified laboratory Documentation :

• Inspection & Testing to be performed by a qualified laboratory as defined

by customer.

• Qualified Laboratory (internal or external) to have Laboratory scope and

documented evidence showing the laboratory is qualified for the type of
measurements or test conducted.

13. Appearance Approval Report :

• Appearance Approval Report (AAR) is needs to be prepare for each part

or series of part for Appearance item only.

• A copy of Appearance Approval Report (AAR) needs to be signed &

approved from customer.
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PPAP Documents (19 Nos)
14. Sample Production Part :

• The supplier shall provide sample product in quantity as par details

provided by customer .

• The sample will be from the same lot of Initial Production Run

15. Master Sample :

• A sample signed off by customer and supplier, that usually used to train
operators on subjective inspection such as Visual Inspection, Audible
Inspection etc.

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PPAP Documents (19 Nos)

16. Checking Aids :

• Checking Aids are the special tool or jig or instrument or equipment

used for checking / measuring the part. A list needs to be submit to
customer (if requested).

17. Customer Specific Requirement :

• The supplier shall have record of compliance to all applicable customer

specific requirements (CSR).

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PPAP Documents (19 Nos)

18. Bulk Material Requirement :

• For Bulk Material, The Bulk material check list must be jointly agreed
upon by the customer and supplier.

19. Part Submission Warrant (PSW) :

• This is the form that summarizes the whole PPAP.

• This form shows the reason for submission (design change, annual
revalidation, etc.).

• The level of documents submitted to the customer.

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PPAP Submission Levels

LEVEL 1 : Submit Warrant And Appearance Approval Report for

Appearance item.

LEVEL 2 : Submit Warrant, Product Sample And Limited Supporting data.

LEVEL 3 : Submit Warrant, Product Sample And Complete Supporting data.

LEVEL 4 : Submit Warrant and other requirement specified by Customer.

LEVEL 5 : Submit Warrant, Product And Complete Supporting data at

Manufacturing location.

Use Level 3 as Default level unless specified by customer.

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PPAP Submission Levels
S. No. Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1 Design Record R S S * R
2 Authorized Engineering Change (note) Documents R S S * R
3 Customer Engineering Approval R R S * R
4 DFMEA R R S * R
5 Process Flow Diagram R R S * R
6 PFMEA R R S * R
7 Control Plan R R S * R
8 Measurement System Analysis Studies (MSA) R R S * R
9 Dimensional Results R S S * R
10 Material / Performance Test Result R S S * R
11 Initial Process Studies R R S * R
12 Qualified laboratory Documentation R S S * R
13 Appearance Approval Report S S S * R
14 Sample Production Part R S S * R
15 Master Sample R R R * R
16 Checking Aids R R R * R
17 Customer Specific Requirement R R S * R
18 Bulk Material Requirement S S S S R
19 Part Submission Warrant (PSW) S S S S R
Legends :
S :- Submit to Customer ;
R :- Retain at organization and make available to customer upon request ;
* :- Retain at organization and submit to customer upon request
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PPAP Submission Status
Approved:

• Indicate all customer and specific requirements are met.

• Supplier has authority of shipping as per schedule / order.

Interim Approval:

• Authorized shipment of Production requirement for limited time or

quantity, only granted when root cause for non conformity is identified
and approval from customer obtained on interim approval.

Rejected:

• PPAP Submission does not meet Customer Requirement.

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PPAP Documents (19 Nos)

Thank You
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