June 15, 2020
A Production Part Approval Process is a standardized process that helps manufacturers and suppliers communicate and approve production designs and processes before, during and after manufacture.
This process will make sure that you and your manufacturer are on the same page. PPAP’s help ensure that the processes used to manufacture parts can be reproduced consistently. This sets some expectations for how PPAP’s must be performed. They must be run identically to the production process with production equipment and tooling, production employees and outputting at a production rate. Setting up the exact conditions the part will run in is crucial to getting a consistent output during the eventual production.
AIAG PPAPs specifically require five levels of submission. All applicable aspects must still be performed by the supplier. The levels just indicate what is submitted to the customer, and if the customer has their own standards, all applicable aspects may not be required. The submission levels are as follows:
Level 1 – Part Submission Warrant (PSW) only submitted to the customer
Level 2 – PSW with product samples and limited supporting data
Level 3 – PSW with product samples and complete supporting data
Level 4 – PSW and other requirements as defined by the customer
Level 5 – PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location
PPAP’s are similar to a strategy or plan, and serve as the direct negotiation between customer and supplier to confirm how each element is satisfied. Not all PPAP’s are the same! Depending on the part and process, it can take considerably more or less time to complete the document. The longer it takes to develop the PPAP, the more costs are incurred by the supplier. Negotiation must take place before the requirement is accepted and the process is put into motion. This ensures that both parties are on the same page with their expectations.
PPAP’s are required under certain circumstances:
PPAP’s are also required annually, so if you are running the same part for years and years, this ensures that the process remains consistent. You may also request a new PPAP at any time during the life of the part or product.
At first glance, this document can seem overwhelming with 18 total elements, but once you know what to look for, you can find all the information you need and more! Note that not all elements are in every PPAP depending on the parts and processes.
Here’s a brief summary on all 18 elements: