Production Part Approval Process - 4th Edition

Welcome to

Production Part
Approval Process
(PPAP)

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Production Part Approval Process - 4th Edition

Course Goal
 To discuss the requirements of the
Production Part Approval Process and
why they are important to suppliers and
customers

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Objectives
This course was designed to enable you
to do the following:
 Define the requirements for PPAP as
they relate to ISO/TS 16949:2002
 Identify and define customer specific
requirements for submission of PPAP

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Objectives (cont’d.)

 Identify when a PPAP submission is

required
 Identify what is required in a PPAP
submission
 Describe the relationship between key
APQP deliverables and PPAP
 Describe the submission process and
required records
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Introductions

 Who are you?

 Describe your company and the
products/services you supply to the
automotive/heavy truck industry
 Discuss any specific question or needs
you have

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Activity
 When you purchase a new vehicle, there
are many items that you will want to
review and approve before you take
delivery of your vehicle
 When you arrive at the dealership, you
inspect the vehicle to make sure it meets
all the requirements stated in your contract
with the dealership. Are there additional
items you expect to receive?
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Activity
1. The vehicle, meeting all it intended requirements

2. _____________________________________

3. _____________________________________

4. _____________________________________

5. _____________________________________

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Activity Conclusion
 Delivery of your new vehicle is more than
just the vehicle itself
 You also require a form of PPAP for your
purchases

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Requirements to use PPAP

 ISO/TS 16949:2002
 7.3.6.3 Product Approval Process
 The Organization shall conform to a product
and manufacturing process approval process
recognized by the customer
 This product and manufacturing process
approval procedure shall also be applied to
suppliers

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Requirements to use PPAP

 Customer Specific Requirements for PPAP
 Some customers may have specific requirements
for submission details including
 When to submit
 What to submit
 Who to submit to
 What format to submit in
 Reference customer requirements for these
details at www.iaob.org or your specific customer
web site

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Forward to the 4th Edition Change

 Effective June 1st, 2006 the 4th edition

replaces the 3rd edition unless otherwise
New
specified by the customer
 PPAP now incorporates the process
approach as used in ISO/TS 16949:2002

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Production Part Approval Process - 4th Edition

Forward to the 4th Edition

 Major changes
 Alignment to ISO/TS 16949:2002
 Relocation of customer specific requirements to
appropriate websites
 Update of Truck OEM requirements
 Revised Part Submission Warrant (PSW)
 Updated specific requirements for:
 Materials reporting and polymeric identification
requirements in the design record
 Process capability index usage
 Definitions for catalog and “black box” parts
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Forward to the 4th Edition

 Major changes (cont.)
 Modified customer notification and submission
requirements to align with OEM requirements
 Clarified and commonized appendices C,D, and E
 Revised tire appendix
 Reorganization and update of Bulk Material
requirements
 Revised glossary

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PPAP Process Flow New

PPAP Process Flowchart Example

CUSTOMER CUSTOMER

Customer Record of
Purchase Order / Approved
Customer-Specific PSW
Requirements
ORGANIZATION

Completion of Submission (or

Customer Project Owner Receipt and
PPAP Resubmission)
Part Design & Approval of
Required of PPAP
Requirements Team Submitted PSW
Items Warrant

Customer Validated
Process Design Completion Process
Gather
Requirements of [PSO / Run at
Information
PSW Rate]

Supplier Initiated
Customer Approved Changes
PPAP Table 4.1
Specifications PSW
Records Customer Initiated
Changes
to Part ,
Specifications, etc.

Customer
Logistics
Requirements

Notes:
1. Activities shown will not always be present.
2. Records shown may be in various media and in various storage locations.

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Introduction
 PPAP defines generic requirements to
determine if all customer requirements
have been attained
 To ensure the process has the potential to
continue to meet those requirements

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Applicability
 Applies to all internal and external
supplier sites of production and service
parts unless otherwise specified by the
authorized customer representative

Review and discuss notes

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Approach
 Shall is mandatory Change

 Should is a recommendation
 Notes are for guidance and understanding
only
 For the purposes of PPAP, the terms and
definitions given in ISO/TS 16949:2002 and
the PPAP glossary apply

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Section 1 - General
 1.1 Submission of PPAP
 The organization shall obtain approval from
the authorized customer representative for:
 New part or product
 Correction of a discrepancy
 Product modified by any engineering change to
the part (delete this)
 Any situation required in section 3

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.1 Significant production run

 For production parts, product for PPAP shall
be taken from a significant production run:
 From 1 to 8 hours of production
 To total a minimum of 300 consecutive parts
 Produced at the production site, at the production
rate, using production tooling, gages, operators,
etc.
 Each unique manufacturing process shall be
represented
 Bulk material samples shall be taken from “steady
state” operation
Review and discuss notes
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Section 2 – PPAP Process Requirements

 2.2 PPAP requirements

New
 Shall meet all requirements listed
 Shall also meet all customer specific
requirements
 Use bulk material checklist
 If any requirements cannot be met, start
corrective action and contact the customer
for disposition New

Review and discuss note

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Section 2 – PPAP Process Requirements

 2.2.1 Design record

 For all saleable product
 Produce a hard copy if electronic to identify
measurements taken
New

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.1.1 Reporting of part material New

composition
 Provide evidence that material reporting is
in accordance with customer requirements
 Note: International Materials Data Systems
available at www.mdsystem.com/index.jsp

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Section 2 – PPAP Process Requirements

New
 2.2.1.2 Marking of polymeric parts
 Use ISO systems: ISO 11469, ISO 1629
 For plastic part weighing at least 100g
 For elastomeric parts weighing at least 200g

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.2 Authorized engineering change

documents
 For changes not yet incorporated into the
product

Discussion: Why is this important?

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Section 2 – PPAP Process Requirements

 2.2.3 Customer engineering approval

 Where specified provide evidence

Review and discuss notes

Discussion: Why is this important?

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Section 2 – PPAP Process Requirements

Change
2.2.4 Design FMEA
For product design responsible
organizations
Use FMEA reference manual
Review and discuss notes

Discussion:
If you are not design responsible, do you need to
obtain a copy of the customers design FMEA?

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Section 2 – PPAP Process Requirements

 2.2.5 Process flow diagram

 In the organization’s format
 Clearly describes the process
sequence and all process steps

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.6 Process FMEA

 Use FMEA reference manual
 Refer to customer specifics if required

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.7 Control Plans

 Defines all methods used for process
control
 Use APQP reference manual

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.8 Measurement systems analysis

 For all new or modified gages and test
equipment
 Use Measurement Systems Analysis
reference manual
New

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.9 Dimensional results

 Provide evidence that all verifications required by
the design record and control plan indicate
compliance
 For each unique manufacturing process
 All dimensions shall be recorded (actual results)
 Include all required information including
 Date
 Part number
 Change level

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Section 2 – PPAP Process Requirements

 2.2.9 Dimensional results (cont.)
 Include all required auxiliary materials used
in conjunction with the part drawing
including
 CMM sheets
 Tracings
 Sketches Change
 Tolerance sheets
 Review and discuss appendix C

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.10 Records of material and

performance test results
 As specified by the design record and control plan
 2.2.10.1 Material test results
Change
 2.2.10.2 Performance test results
 Review and discuss appendices D and E

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.1 Initial process studies

 Level of initial process capability shall be
acceptable prior to submission
 The organization shall obtain customer
concurrence on the index used prior to submission
 For all special characteristics
Change

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.2 Quality indices

 Shall be summarized with capability or
performance indices if applicable
New

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.3 Acceptance criteria for initial

study Change
 Use the following acceptance criteria
Index > 1.67 Process currently meets
acceptance criteria
1.33 < index < 1.67 Process may be acceptable,
contact customer

Index < 1.33 Process does not meet acceptance

criteria, contact customer

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.4 Unstable process

 The organization shall notify the customer of any
unstable processes and start corrective action
prior to submission

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.5 Process with one sided specification

or non-normal distributions
 Organization shall determine with the customer,
alternative acceptance criteria

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.11.6 Action to be taken when acceptance

criteria are not satisfied
 Contact the customer
 Submit corrective action
 Modify the control plan to use 100% inspection

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.12 Qualified laboratory documentation Change

 Shall use qualified laboratories as defined by

customer requirements
 When external laboratories are use, the
organization shall submit results on the
laboratories letterhead

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Section 2 – PPAP Process Requirements

 2.2.13 Appearance Approval Report

 Used when parts have appearance requirements
 Shall accompany the PSW for final submission
 Review and discuss appendix B

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.14 Sample production parts
 Provide parts as specified by the customer

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Section 2 – PPAP Process Requirements

 2.2.15 Master sample
 Shall be retained by the organization for as long as the
PPAP records or:
 Until a new master sample is produced
 Longer when required by the design record
 Shall be identified as such and show customer
approval date on the sample
 The organization shall retain a master sample for each
position of a multiple cavity die, mold, tool or pattern, or
production process unless otherwise specified by the
customer
Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.16 Checking aids
 Submit when requested by the customer
 Shall agree with the part dimensional
requirements
 Shall document all released engineering changes
 Shall be included in MSA studies

Review and discuss notes

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Section 2 – PPAP Process Requirements

 2.2.17 Customer specific requirements

 Organization shall keep records of conformance to
all customer specific requirements
 Shall be documented on the bulk materials
requirements checklist

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Section 2 – PPAP Process Requirements

Change

 2.2.18 Part Submission Warrant (PSW)

 Completed for each customer part number
 Mold, cavity, die, each production stream, shall be
documented on the PSW
 All required information shall be available or
included in the submission (levels 2-4) regardless
of submission level
 2.2.18.1 Part Weight
 Shall record the part weight on the PSW in
kilograms to four decimal places
 Review and discuss appendix A

Review and discuss notes

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Production Part Approval Process - 4th Edition

Section 3 – Customer Notification and

Submission Requirements
Change
 3.1 Customer Notification
 The organization shall notify the authorized
customer representative of any planned
changes to design, process, or site (See
table 3.1)
 Upon notification and approval, and after
change implementation, submission is
required unless otherwise specified
Review and discuss notes

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Section 3 – Customer Notification and

Submission Requirements (Table 3.1)
Examples of changes requiring notification Clarifications
1. Use of other construction or material For example, other construction as documented on
than was used in the previously approved a deviation (permit) or included as a note on the
part or product design record and not covered by an engineering
change.
2. Production from new or modified tools This requirement only applies to tools, which due
(except perishable tools), dies, molds to their unique form or function, can be expected
patterns, etc. including additional or to influence the integrity of the final product. It is
replacement tooling not meant to describe standard tools (new or
repaired), such as standard measuring devices,
drivers (manual or power), etc.
3. Production following upgrade or Upgrade means the reconstruction and/or
rearrangement of existing tooling or modification of a tool or machine or to increase the
equipment. capacity, performance, or change its existing
function. This is not meant to be confused with
normal maintenance, repair or replacement of parts,
etc., for which no change in performance is to be
expected. Rearrangement is defined as activity that
changes the sequence of product/process flow from
the documented in the process flow diagram.

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Section 3 – Customer Notification and

Submission Requirements (Table 3.1)
Examples of changes requiring notification Clarifications
4. Production from tooling and equipment Production process tooling and /or equipment
transferred to a different plant site or from an transferred between buildings or facilities at one or
additional plant site. more sites.

5. Change of supplier for parts, non- The organization is responsible for approval of
equivalent materials, or services (e.g., heat- supplier provided material and services.
treating, plating).

6. Product produced after the tooling has For product that has been produced after tooling
been inactive for volume production for has been inactive for twelve months or more:
twelve months or more. Notification is required when the part has had no
change in active purchase order and the existing
tooling has been inactive for volume production for
twelve months or more. The only exception is when
the part has low volume, e.g., service or specialty
vehicles. However a customer may specify certain
PPAP requirements for service parts.

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Section 3 – Customer Notification and

Submission Requirements (Table 3.1)
Examples of changes requiring notification Clarifications

7. Product and process changes related to Any changes, including changes at the suppliers to
components of the production product the organization and their suppliers, that affect
manufactured internally or manufactured by customer requirements, e.g., fit, form, function,
suppliers. performance, and durability.

8. Change in test/inspection method – new For change in test method, the organization should
technique (no effect on acceptance criteria) have evidence that the new method has
measurement capability equivalent to the old
method.

Additionally, for bulk materials: These changes would normally be expected to have
9. New source of raw material from new or an effect on the performance of the product.
existing supplier.
10. Change in product appearance attributes

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Section 3 – Customer Notification and

Submission Requirements
 3.2 Submission to Customer
 The organization shall submit for PPAP prior to the
first production shipment in the following situations
unless waived by the authorized customer
representative (table 3.2)
 The organization shall review and update all
applicable items in the PPAP file regardless of
formal submission. If waived, the PPAP file shall
contain the name of the authorized customer
representative granting the waiver
Review and discuss notes

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Section 3 – Customer Notification and

Submission Requirements
Requirement Clarifications

1. A new part or product (i.e. a specified part, Submission is required for a new product (initial release) or a
material, or color not previously supplied to previously approved product that has a new or revised product/part
the customer) number (e.g., suffix) assigned to it. A new part/product or material
added to a family may use appropriate PPAP documentation from a
previously approved part within the same
product family.
2. Correction of a discrepancy on a previously Submission is required to correct any discrepancies on a previously
submitted part. submitted part. A “discrepancy” can be related to:
• The product performance against the customer requirements
• Dimensional or capability issues
• Supplier issues
• Approval of a part replacing an interim approval
• Testing, including material, performance, or engineering validation
issues

3. Engineering change to design records, Submission is required on any engineering

specifications, or materials for production change to the production product/part design
product/part numbers (s). record, specifications or materials.

Additionally, for Bulk Materials:

4. Process technology new to the
organization,
not previously used for this product.

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Section 4 – Submission to Customer – Levels

of evidence
 4.1 Submission Levels
Level 1
Warrant only (and for designated appearance items, an
Appearance Approval Report) submitted to the customer.

Level 2
Warrant with product samples and limited supporting data
submitted to the customer.

Level 3
Warrant with product samples and complete supporting data
submitted to the customer.

Level 4 Warrant and other requirements as defined by the customer.

Level 5
Warrant with product samples and complete supporting data
reviewed at the organization’s manufacturing location.

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Section 4 – Submission to Customer – Levels

of evidence
 4.1 Submission Levels
 Level 3 is the default level
 Minimum requirements for bulk materials
 PSW
 Bulk materials checklist

Review and discuss notes

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Section 4 – Retention/Submission requirements

table 4.2
Requirement Level 1 Level 2 Level 3 Level 4 Level5

Design Record R S S * R
1. - for proprietary components/details R R R * R

- for all other components/details R S S * R

2. Engineering Change Documents, if any R S S * R

3. Customer Engineering approval, if required R R S * R

4. Design FMEA R R S * R

5. Process Flow Diagrams R R S * R

6. Process FMEA R R S * R

7. Control Plan R R S * R

8. Measurement System Analysis Studies R R S * R

9. Dimensional Results R S S * R

10. Material, 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 Product R S S * R

15. Master Sample R R R * R

16. Checking Aids R R R * R

17. Records of Compliance with requirements R R S * R

18. Part Submission Warrant (PSW) and Bulk materials req’s S S S S R

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Section 5 – Part Submission Status

 5.1 General
 Upon approval of submission, assure that
future production continues to meet
requirements

Review and discuss notes

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Section 5 – Part Submission Status

 5.2 Customer PPAP Status

 5.2.1 Approved
 Commence shipping based on customer schedules
 5.2.2 Interim Approval
 Shipment for limited time or quantity basis based on:
 Clearly defined non-compliance by the organization
 Prepared action plan by the organization agreed upon by the
customer
 5.2.3 Rejected
 Does not meet customer requirements
 Shall be corrected and submission approved prior to production
quantities being shipped

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Section 6 – Record Retention

 Shall be maintained regardless of submission

level for the length of time the part is active
(see glossary) plus one calendar year
 Shall ensure that appropriate PPAP records
from superseded PPAP part files are included
or referenced in the new PPAP part file

Review and discuss notes

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Appendix A – Part Submission Warrant

New
 Completed for each customer part number
 Mold, cavity, die, each production stream, shall be
documented on the PSW
 All required information shall be available or included
in the submission (levels 2-4) regardless of level
 Changes in the PSW include
 General submittal information
 Material reporting
 Declaration
 Tagging of customer tools

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Appendix B – Appearance Approval Report

 Used when parts have appearance

requirements

 Shall accompany the PSW for final submission

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Appendix C, D, and E
Change

 Dimensional Results
Change

 Material Test Results

Change

 Performance Test Results

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Appendix F – Bulk Material Requirements

 F.1 Introduction
 The organization shall comply with requirements or
use as guidance
 Requirements are minimum at the discretion of
organization and /or customer
 F.2 Applicability
 The organization shall apply PPAP to suppliers
which have special characteristics

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Appendix F – Bulk Material Requirements

 F.2 Applicability
 Examples of bulk materials

Adhesives Sealants
Engine Coolants Fabrics
Ferrous metals Non Ferrous metals
Bulk steel Foundry materials
Fuels Glass
Lubricants Polymers

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Appendix F – Bulk Material Requirements

 F.3 Bulk Materials Requirements Checklist

 Required PPAP elements are defined in this Change
checklist
 Customer specific requirements shall be
included
 F.4 Design Matrix
 Shall be prepared prior to DFMEA when
required
 Determines complex interactions of formula
ingredients

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Appendix F – Bulk Material Requirements

 Design FMEA
 Process FMEA
 Special Characteristics
 Control Plan
 Measurement Systems Analysis
 Initial Process Studies
 Master Sample
 Interim Approval
 Customer Plant Connection (delete)

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Appendix G – Tire Specific Requirements

 G.1 Introduction and Applicability

 Shall comply with all requirements of PPAP
 Appendix to be used for guidance and clarification
Change
 G.2 Guidelines for PPAP requirements
 G.3 Submission to Customer

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Appendix H – Truck Industry Requirements

Change
 Introduction
 Shall comply with all PPAP requirements
 Use appendix for guidance
New
 Applicability
 Customer has the right to request PPAP to re-
qualify a production component
 Feature based process or part number
generated components are qualified using the
highest content configuration
 Organization shall submit PPAP for bulk
materials and catalog parts when requested by
the customer
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Appendix H – Truck Industry Requirements

Change
 Significant production run
 Potential process issues shall be identified in the
PFMEA Change

 Dimensional results
 Checked prints are not acceptable
New
 Material test
 Organization shall submit DVP&R
Change
 Quality Indices
New
 Master sample
 Shall be retained after PPAP when specified by
customer

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Appendix H – Truck Industry Requirements

Change
 Part submission warrant
New
 Part weight
 Shall record the part weight on the PSW in kilograms
to four decimal places
Change
 Customer notification
 Organization shall notify the customer of any
planned design or process changes
 Use product/process change notification

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Glossary

 For the purposes of PPAP, the terms and definitions

given in the PPAP glossary apply
 Examples of changes
 Accredited Laboratory
 Authorized Customer Representative
 Black Box
 Organizations
 Process Flow Diagram
 Production Rate
 Specification

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Conclusion

 Define the requirements for PPAP as they relate to

ISO/TS 16949:2002
 Identify and define customer specific requirements
for Submission of PPAP
 Identify when a PPAP submission is required
 Identify what is required in a PPAP submission
 Describe the relationship between key APQP
deliverables and PPAP
 Describe the submission process and required
records

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