PPAP
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Production Part Approval Process:
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The Production Part Approval Process (PPAP) outlines the methods used for approval of production and service commodities, including bulk materials, up to and including part submission warrant in the Advanced Quality Planning process. The purpose of the PPAP process is to ensure that suppliers of components comply with the design specification and can run consistently without affecting the customer line and improving the quality systems. PPAP ensures that you will achieve the first time quality and will lower down the cost of quality.
PPAP is an acronym for Production Part Approval Process.
The Production Part Approval Process is used in the automotive supply chain to establish confidence in component suppliers and their production processes, by demonstrating that:-
"....all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate."
PPAP Approval
The result of the PPAP process 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 approval by the supplier and customer. The form that summarizes this package is called PSW (Part Submission Warrant). The approval of the PSW indicates that the supplier responsible person (usually the Quality Engineer) has reviewed this package and that the customer has not identified any issues that would prevent its approval.
The documentation on the PPAP package is closely related to the Advanced Product Quality Planning process (APQP) 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.
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 clients 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
Production Part Approval Process (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.
PPAP Elements
Design Records
Authorized Engineering Change Documents
Engineering Approval
DFMEA
Process Flow Diagram
PFMEA
Control Plan
Measurement System Analysis Studies
Dimensional Results
Records of Material / Performance Tests
Initial Process Studies
Qualified Laboratory Documentation
Appearance Approval Report
Sample Production Parts
Master Sample
Checking Aids
Customer Specific Requirements
Part Submission Warrant (PSW)