GlossaryKind of term: Standard and conventionPPAP (production part approval process)
What is PPAP?
PPAP is the automotive approval procedure in which a supplier shows that its production process makes the part to requirements, before series supply starts.
In full it is the production part approval process, and approval is granted per production part. With documents, measurements and samples you show that the part meets the requirements and that your process can keep doing so in series. The package is summed up in the part submission warrant, the form the supplier signs and on which the customer records its approval decision.
What does the standard say about PPAP?
The procedure is set out in the AIAG PPAP manual, of which the fourth edition of 2006 has long been the current one, supplemented by customer-specific requirements. The manual lists 18 elements, among them the design record, the process flow diagram, the process FMEA, the control plan, measurement system analysis, dimensional results, initial process studies, sample parts and the part submission warrant itself. The customer chooses a submission level from 1 to 5; without agreement, level 3 applies. German customers often ask for the comparable PPF procedure under VDA volume 2.
How does PPAP work in practice?
PPAP is work before the first batch: drafting the FMEA and control plan, running parts under production conditions, measuring parts from that run for the process study and assessing the gauges with a measurement system analysis. How large the run and the study are follows from the manual and the customer's requirements. It is usually quoted as a one-off item beside the piece price; spread it over the piece price and recovery depends on the volumes actually called off. A drawing change, different tooling, another site or a new subcontractor can require a fresh submission.
What is PPAP often confused with?
PPAP is not a first article inspection: that shows one part meets the drawing, while PPAP also shows that the process stays stable in series. The aerospace first article inspection under AS9102 does not ask for a process study either.
Frequently asked questions
What is the difference between PPAP and a first article report?
A first article report shows that one part meets the drawing. PPAP also shows that your process keeps doing so in series, with process documents, a process study, a measurement system analysis and samples from a production run.
How do I include PPAP in a quote?
As a one-off item beside the piece price, covering the hours for documents, the production run, the measuring and the samples. State the submission level, because level 3 asks far more than level 1.
Which PPAP level applies if the customer names none?
Under the manual, level 3: the part submission warrant with samples and full supporting data. Level 1 is essentially the warrant alone; at level 5 the customer reviews everything at your site.