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15 views

PPAP - info

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Vilas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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What is Production Part Approval

Process (PPAP)?
PPAP (pronounced P-PAP) is a design & manufacturing inspection
process used to verify a supplier's ability to reliably and repeatedly
produce a part or set of parts for mass production.

PPAP validates a production process by inspecting parts before, during,


and after a production run.

The PPAP report reviews 18 requirements such as design records,


authorized engineering changes, engineering approval, dimensional
results, control plan, and more.

PPAP is part of the five Core Tools for effective quality management
with APQP, FMEA, MSA, and SPC being the other core tools.

Purpose of PPAP:
1. Validating supplier’s ability.
2. Understanding customer requirements.
3. Establishing a reliable and repeatable process & agreement.
4. Reducing cost and having faster time to market.
5. Maintaining expectations & compliance on both sides.

Why is PPAP important?


PPAP is important for three things:

1. For customers (the OEM) to validate the supplier’s process to


supply the product at the required quality and quantity under
normal production conditions.
2. For suppliers to understand the customer’s product requirements
and specs.
3. For both customer and supplier to have agreed-to and
documented expectations.

The manufacturing industry is highly competitive. Reducing cost,


increasing faster time to market, and maintaining or improving quality
are three tenets of any successful company.

Getting quality parts done right and taking corrective action earlier in
the lifecycle saves significantly more time and money when compared
to rework, scrap, and the dreaded recall.

Every OEMs goal is to have a reliable and repeatable process,


and PPAP enforces that standard.

Common problems PPAP detects:


1. Wrong or poor production process (e.g. equipment).
2. Incorrect or ambiguous product design.
3. Wrong or inconsistent quality of material.
4. Inconsistent quality control.

Who does the PPAP and when is It


required?
In general, suppliers or the production team create the PPAP report for
the customer to review. The process is usually done in close
cooperation with the OEM’s quality team.

PPAP is typically required for the production of new parts or when there
is a change to the product or process:

1. A new part or product.


2. Product changes/corrections: design, materials, supply, and
function.
3. Process changes/corrections: method, tools, location, and
inspection criteria.
4. Inactive tooling for more than one year.

What’s in a PPAP Document


The PPAP report reviews 18 requirements called elements.

PPAP 18 Elements:
1. Design Records: A copy of the drawing or model provided by
customer.
2. Engineering Change Documents: Detailed description of
changes of parts from previous revisions called Engineering
Change Notice.
3. Customer Engineering Approval: Customer approval of
sample production parts.
4. Design Failure Mode and Effects Analysis
(DFMEA): Prediction of a product's potential design failure.
5. Process Flow Diagrams: All steps in manufacturing process
including components, measurement, and inspection.
6. Process Failure Mode and Effects Analysis
(PFMEA): Prediction of a potential process failure that could occur
during production.
7. Control Plan: Details the plan for how quality will be
implemented to ensure a stable and reliable process.
8. Measurement System Analysis (MSA): Conformance to
customer’s ISO or TS standard. Usually Gage R&R for critical
impact characteristics to control repeatability and reproducibility
and confirmation that gages are calibrated to measure these
characteristics to control measurement bias.
9. Dimensional Results: A list of every dimension noted on the
ballooned drawing or model with pass/fail assessment.
10. Material / Performance Test Results: Summary of every
test performed on the part, usually in the form of DVP&R (Design
Verification Plan and Report).
11. Initial Process Studies: Shows that critical processes are
reliable. Includes SPC (statistical process control) charts.
12. Qualified Laboratory Documentation: All industry
certifications for validation testing.
13. Appearance Approval Report (AAR): Customer approval
on final product appearance including color, texture, fit, and more.
14. Sample Product: Sample from initial production run.
15. Master Sample: Sample part signed off by customer and
supplier.
16. Checking Aids: Detailed list of all tools used to inspect and
measure parts.
17. Records of Compliance with Customer-Specific
Requirements: List of customer’s specific requirements for PPAP
process.
18. Part Submission Warrant (PSW): Summary of entire
PPAP submission.

The PPAP report has 5 levels of submissions with Level 3 as the default
level of PPAP submission approval.
PPAP 5 Levels of Submission:
 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 Retention and Submission Requirements Table


Requirements Level 1 Level 2 Level 3 Level 4 Level 5
1. Design Record R S S * R

- for proprietary
R R R * R
components/details

- for all other


R S S * R
components/details
2. 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 Diagrams R R S * R
6. Process FMEA R R S * R
7. Control Plan R R S * R
8. Measurement System Analysis 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 R S S * R
Documentation
13. Appearance Approval Report S S S * R
14. Sample Report R S S * R
15. Master Sample R R R * R
16. Checking Aids R R R * R
17. Records of Compliance w/
R R S * R
Customer-Specific Requirements
18. Part Submission Warrant (PSW) |
S S S * R
Bulk Material Checklist

S = Organization must submit to the customer and retain a copy of records or


documentation items at appropriate locations.

R = Organization must retain at appropriate locations and make available to the


customer upon request.

* = Organization must retain at appropriate location and submit to customer upon


request.

Who Governs PPAP Standards?


The Automotive Industry Action Group (AIAG) has a common PPAP
standard, although individual OEMs (original equipment manufacturer)
can have their own distinct requirements.

AIAG memberships includes Ford, General Motors, Chrysler, Toyota,


Honda, Nissan, Volkswagen, Caterpillar, and over 800 OEMs, parts
manufacturers, and service providers.

Although primarily used in the automotive industry, other industries


such as aerospace & defense, consumer goods, heavy industries,
medical, electronics and more have been quick to adopt PPAP or a
derivative of it.

The PPAP manual is currently in its 4th edition (Publication date: March
2006).

Digitizing the PPAP process:


Automatic ballooning &
measurement results
PPAP isn't easy.

Especially with creating PPAP reports manually.

With a model-based definition (MBD) PPAP creation time can drastically


be reduced through automatic ballooning and measurement results.

MBD is a growing industry practice of having the 3D CAD model be the


“single source of truth.”

This means the CAD model along with semantic product and
manufacturing information (PMI) can drive the PPAP report, GD&T, bill of
materials, notes, engineering change orders etc. for an improved
method of inspection generation and other manual processes that can
be automated.

The power of MBD-based PPAP is the human and machine


readability factor. With 2D drawings, data is for human consumption
which presents two major problems: reliance on human process &
interpretation and data that is underutilized.
Learn more about MBD PPAP Download: MBD-Based Inspection
Reporting PDF

For example, if a large company with multiple suppliers receives the


same drawing, most likely, the company will get back 5 different PPAP
documents with different GD&T interpretations from the suppliers.

Not the headache we want to deal with.

MBD-based PPAP coming from the company first establishes the


specification of the process and product more explicitly which ensures
uniformity between different suppliers.

Also, quality and inspection teams are often viewed as pass/fail


departments, yet they have valuable data that can help improve
business products and problems.
MBD introduces data back into the ecosystem for improved designs,
improved parts, and improved operations done quicker, cheaper, and
more efficiently.

MBD PPAP Benefits:


1. Automated: No need for human transcription or interpretation.
2. Build and optimize a reliable and repeatable process.
3. Data mapped back to the single source of truth.
4. Start of the digital transformation from design to manufacturing.
5. Valuable data to mined for analytics and business insights.

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