PPAP: the 5 submission levels and 18 elements
PPAP (Production Part Approval Process) is the automotive procedure by which a supplier demonstrates that it understands all customer engineering requirements and that its manufacturing process can consistently produce conforming product at the quoted production rate. The process is defined in the AIAG PPAP manual; the current edition is the 4th.
When is a PPAP submission required?
- for a new part or product,
- after correcting a previous discrepancy,
- after a product or process change: new material or sub-supplier, new or relocated tooling, a new manufacturing site, a change of technology,
- when tooling has been inactive for more than 12 months, or whenever the customer requests it.
The 5 submission levels
- Level 1: warrant (PSW) only, plus an appearance approval report (AAR) for appearance items.
- Level 2: warrant with product samples and limited supporting data.
- Level 3: warrant with product samples and complete supporting data. This is the default level unless the customer specifies otherwise.
- Level 4: warrant and other requirements as defined by the customer.
- Level 5: warrant with product samples and complete supporting data reviewed at the supplier’s manufacturing location.
What does each level require?
| Element | 1 | 2 | 3 | 4 | 5 |
|---|---|---|---|---|---|
| 1. Design records | R | S | S | * | R |
| 2. Authorized engineering change documents | R | S | S | * | R |
| 3. Customer engineering approval | R | R | S | * | R |
| 4. Design FMEA | R | R | S | * | R |
| 5. Process flow diagram | R | R | S | * | R |
| 6. Process FMEA | R | R | S | * | R |
| 7. Control plan | R | R | S | * | R |
| 8. Measurement system analysis (MSA) | R | R | S | * | R |
| 9. Dimensional results | R | S | S | * | R |
| 10. Material and performance test results | R | S | S | * | R |
| 11. Initial process studies | R | R | S | * | R |
| 12. Qualified laboratory documentation | R | S | S | * | R |
| 13. Appearance approval report (AAR) | S | S | S | * | R |
| 14. Sample production parts | R | S | S | * | R |
| 15. Master sample | R | R | R | * | R |
| 16. Checking aids | R | R | R | * | R |
| 17. Customer-specific requirements | R | R | S | * | R |
| 18. Part submission warrant (PSW) | S | S | S | S | R |
S = submit to the customer; R = retain at the supplier and make available on request; * = the customer defines whether to submit or retain.
Practical tips
- All documents must be prepared even when they are only retained (R): the level only determines what is sent to the customer.
- Dimensional results must cover every dimension and note on the drawing, typically on at least one part per cavity or production line.
- For initial process studies on special characteristics, Ppk ≥ 1.67 is the usual expectation; between 1.33 and 1.67 the customer may accept with conditions.
- Customer-specific requirements (such as OEM supplier manuals) always take precedence over the general rules.
- In the German automotive industry, PPF (Produktionsprozess- und Produktfreigabe) according to VDA 2 serves a similar purpose, with 3 submission levels.