1.

INTRODUCTION

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."
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 supplier’s 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 Supplier’s 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.

Scrap Inspection Testing

Raw Raw Finished

goods good Manufacturing Process good
received warehous warehousing
e
Non Rework To market
confirming
product flow

Fig 2 Process flow diagram

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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 supplier’s 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 usually
shows 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 the Part 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 supplier’s 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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