PPAP is short for Production Part Approval Process, and was created and first utilised by the automotive industry. It is used as a risk identification and mitigation process, provided to the costumer as evidence of a repeatable process.
There are 5 levels of PPAP as defined below.
- Level 01: Only require a Part Submission Warrant (PSW).
- Level 02: Require PSW and product sample with limited supporting data.
- Level 03: Require PSW and complete set of supporting data.
- Level 04: Require PSW and other requirement defined by the costumer.
- Level 05: Require PSW and product sample with complete set of supporting data.
If the default level of submission isn’t specified, it is by default required a level 03 PPAP.
- Level 01 – Is typically used for suppliers who have been supplying same part without any issues.
- Level 02 – Is used for slight modification, which does not change the manufacturing process.
- Level 03 – Is used for a new part or new supplier
- Level 04 – Is typically for a part with significant design changes.
- Level 05 – Is for suppliers with lot of previously known issues
Below are the elements that are included in a Production Part Approval Process.
- Design documentation
- Engineering change documents
- Customer engineering approval
- Design FMEA
- Process flow diagrams
- Process FMEA
- Control plan
- Dimensional analysis
- Material performance reviews
- Initial process studies
- Qualified laboratory documentation
- Sample product
- Master sample
- Checking aids
- Records of compliance
When is PPAP Used
A Production Part Approval Process is needed for any new part, or when a part or process is being changed. The PPAP is generated by the supplier, and as they are not all the same, the expectation should be agreed between costumer and supplier.
If you are interested in Production Part Approval Process or need training in some of the elements for your employees, then contact us for a free consultation.
Alternatively you can continue to our quality training page for an overview of other training we provide.Go to Quality Training