PPAP-Production Part Approval Process

Learn how the production part approval process (ppap) bridges supplier and customer through product and process validation, gathering customer inputs and preparing the paperwork for approval of regular supplies.

Identify when to submit the ppap to the customer, including changes to part design or manufacturing process, new products, corrections of discrepancies, and tooling or material notifications.

Explore PPAP submission levels 1 through 5, detailing appearance approvals, product samples, and supporting data requirements. Emphasize customer-defined criteria and manufacturing locations in level five.

Join a Pepsi significant production run (1–8 hours, at least 300 consecutive parts) featuring stage-wise inspection, testing, and a site release guided by production rate, tools, materials, and manpower.

Explain bulk materials, including liquids, solids, gases, and other forms, used as production materials, and show how buyers set acceptance criteria through material descriptions and purchase orders for PPAP completion.

Identify critical and significant characteristics in ppap, shown as special characteristics on drawings with cross-triangle symbols, learn how these affect product parameters, government regulations, fit function, statistical process control.

Define the design record as the customer approved drawing and data linking geometrical tolerances, standards, materials specifications, and special processes to the product drawing.

Create an authorized engineering change document recording changes not yet in the design record but in the product part or tooling, with minutes of meeting and customer email as evidence.

Obtain customer engineering approval in PPAP by attaching evidences, minutes or emails, and document supplier changes per customer input while securing approvals for bulk materials from approved sources.

Learn how to craft a process flow diagram that schematically represents workflow, using customer-specified formats and geometric symbols to capture product and process characteristics.

Assess risks in production with PFMEA by identifying failure modes, effects, and causes; evaluate controls and control plans, calculate risk priority numbers, and prioritize corrective actions to mitigate defects.

Explain the control plan as a documented, three-phase approach (prototype, pre-launch, production) detailing product and process characteristics, tolerances, methods, and a nonconformance reaction plan.

Master measurement system analysis fundamentals, including accuracy, precision, and instruments. Learn to perform gauge repeatability and reproducibility studies, data collection, and gr&r acceptance criteria.

Describe how dimensional requirements are documented in PPAP, with ballooned drawings linked to unique numbers for dimensional tests and layout inspections, plus master samples for reference.

Learn to document material tests in a design verification plan and report that address customer expectations and capture reliability, performance, and dimensional inspections with traceable certificates.

Explore how initial process studies apply statistical process control, X-bar charts, and capability indices (BP, PPK, CPC) to assess variable and attribute data against tolerance limits for PPAP submissions.

Define the laboratory scope and customer expectations for qualified laboratory documentation. Verify that tests are conducted at accredited laboratories with proper certificates and reports.

Assess the appearance approval report (AAR) for all visible outer vehicle components, review paint or coating finishes, color codes, and samples, and submit design records for initial approval.

Define production standards using the master sample in PPAP. Suppliers submit samples per customer specs, retain the master sample, and provide inspection reports to verify appearance and attributes.

Identify and assemble the checking aids list for PPAP submissions, including gauges, measuring instruments, and templates, with supplier details, calibration frequency, and MSA considerations.

Identify, implement, and audit customer-specific requirements (CSR) set by the customer, and follow vendor manuals that specify SOPs, control plans, raw material control plans, and customer-specific order requirements.

Learn how to prepare a part submission warrant (psw) by selecting submission levels based on supplier expertise, quality management, and part criticality, with approvals for customer records.

Capture and retain production and part approval records for the active period plus one year, identify master samples, and tag them with the customer approval date in a single file.

Explore real-life case study of ppap procedures, including customer-specific requirements, templates, change notifications, and control plans guiding initial sample testing and product approval.