Production part approval process (PPAP) is a standardized quality assurance process used primarily in the automotive supply chain for establishing confidence that a supplier's production processes can consistently produce parts meeting customer requirements. Although individual manufacturers have their own particular requirements, the Automotive Industry Action Group (AIAG) has developed a common PPAP standard as part of the Advanced Product Quality Planning (APQP) which encourages the use of common terminology and standard forms to document project status and minimize the risk of failure. The PPAP process is designed to demonstrate that a supplier has developed their design and production process to meet the client's requirements, minimizing the risk of failure by effective use of APQP. Requests for part approval must therefore be supported in official PPAP format and with documented results when needed. The purpose of any Production Part Approval Process (PPAP) is to:
Ensure that a supplier can meet the manufacturability and quality requirements of the parts supplied to the customer Provide evidence that the customer engineering design record and specification requirements are clearly understood and fulfilled by the supplier Demonstrate that the established manufacturing process has the potential to produce the part that consistently meets all requirements during the actual production run at the quoted production rate of the manufacturing process.
Critical elements of the Production Part Approval Process Design record with all specification Authorized engineering change number (ECN) Customer Engineering Approval Process is defined Process is documented Linkages of process are established Process is monitored, analyzed, and improved based on data Records are created, maintained, and retained Validation Test Report Control Plan PFD (Process Flow Diagram) Lab Test Report DFMEA (Design Failure Mode and Effects Analysis) PFMEA (Process Failure Mode and Effects Analysis) MSA Study (measurement system analysis) SPC (Statistical Process Control)
PPAP approval PPAP 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 certification / sign-off by the supplier and approval / sign-off by the customer. The form that summarizes this package is called PSW (Part Submission Warrant). The signature in the customer certification area of the PSW indicates that the supplier-responsible person (usually the Quality Engineer or Quality Manager) has reviewed this package and that the customer-responsible person (usually a Customer Quality Engineer or Customer Quality Manager) 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 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 the AIAG, 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. Details of 'customer specific' requirements may be found on the International Automotive Task Force (IATF) website or supplier portals provided by the vehicle manufacturers. 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:
The client's requirements have been understood; The product supplied meets those requirements; The process (including sub suppliers) is capable of producing conforming product; 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. 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. The term ISIR (initial sample inspection report) is being used by German companies like VW and BMW. ISIR form is standardized by Verband der Automobile industries e. V., short VDA, a German interest group of the German automobile industry, both automobile manufacturers and automobile component suppliers. The term is also used by some other companies like Hyundai and Kia. In fact, ISIR is like the Warrant and Inspection Report of PPAP document package. PPAP document package includes some other document such as PFMEA, control plan, drawing, MSA, capability data etc. Besides ISIR document, other documents like that of PPAP is normally required by Volkswagen and Hyundai for release of a product and process. The PPAP is like the older ISIR plus a lot more, unless the customer has a specific requirement for using their ISIR within their system. ISIR is a summary of the initial sample being presented at what ever state. The PSW is supported and validated by the ISIR. This does not mean the product being presented is under serial conditions but just states with evidence the current status. PPAP is the confirmation that the product meets the customer requirements for series production. The PPAP will be considered signed when a full PSW is approved by the customer and added to the PPAP folder. The PSW would always be supported with an ISIR but the PPAP is only considered approved when a FULL PSW is endorsed with an ISIR. In essence the PSW and ISIR are part of PPAP or VDA and can even be outside of PPAP in cases such as first off tool parts which should be submitted in most cases with a PSW and ISIR but will not be approved in PPAP until series conditions are met.
PPAP elements
Below is the list of all 18 elements, and a brief description of them.
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