Purpose of

PPAP ?
The purpose of PPAP is to determine if
all customer engineering design record
and specification requirements are
properly understood by the organization
and that the manufacturing process has
the potential to produce product
consistently meeting these
requirements during an actual
production run at the quoted production
 Submission Requirements :
– The organization shall obtain approval from the
authorized customer representative for :
1. A new part or Product
2. Correction of a discrepancy on a previously submitted part.
3. Product modified by an engineering change to design records,
specifications, or materials.
4. Any situation given below :
– Production from new or modified tools ,dies, molds, patterns
etc.,
– Production Ramp-up , Re-arrangement of existing tooling or
equipment.
– Production from tooling and equipment transferred to a
different plant site or from an additional plant site.
– Change of organization .
– Product produced after the tooling has been inactive for
volume production for twelve months or more.
– Product or Process changes at sub-vendors .
– Change in test or inspection method – new technique.
 Significant Production Run :

– Minimum 300 Consecutive parts unless

otherwise specified by the authorized
Customer representative .
− This production run shall be conducted using :
• Production Tooling .
• Production gauging.
• Production process.
• Production materials.
• Production operators.
 PPAP Requirements :
1.Design Record
2.Authorized Engineering change
documents.
3.Customer Engineering Approval.
4.DFMEA ( if the Organization is Product design responsible ) .
5.Process Flow Diagram .
6.PFMEA
7.Control Plan.
8.Measurement System Analysis Studies.
9.Dimensional Results.
10.Records of Material /Performance Test
Results.
11.Initial Process Studies .
12.Quality Laboratory Documentation.
13.Appearance Approval Report (AAR).
14.Sample Production Parts.
15.Master Sample .
16.Checking Aids.
17.Customer Specific Requirements.
18.Part Submission Warrant ( PSW ).
Details of the PPAP Requirements :
1.Design Record :
– The organization shall have the design record
for the saleable product/part.
– The organization shall produce a hard copy to
identify measurements taken.
– Reporting of part material composition .

2.Authorized Engineering Change

Documents:
– Engineering change documents for those
changes not yet recorded in the design record
but incorporate in the product ,part or tooling.
3.Customer Engineering Approval :
– Where specified by the customer , the
organization shall have evidence of customer
engineering approval.

4.Design FMEA :
– To be submitted by the organization , if it is
design responsible.

5.Process Flow Diagram :

– Shall clearly describe the process steps and
sequence as appropriate and shall meets the
specified customer needs, requirements and
expectations.
6.PFMEA :
– The organization shall develop a Process
FMEA in accordance with ,and compliant to
customer specified requirements .

7.Control Plan :
– The organization shall have control plan that
defines all methods used for process control
and complies with customer-specified
requirements.

8.Measurement System Analysis Studies

:
– The organization shall have applicable
measurement system analysis studies .
– Gauge R&R ,bias, linearity ,stability , for all
new or modified gages ,measurement and
test equipment.

Criteria of acceptance :

− Gauge R& R shall be less than 10%.

9.Dimensional Results :
– Evidence of dimensional results indicate
complience with the Design records and
control plan.
– Dimensional results of each unique mfg
process e.g., cells ,cavities ,molds or dies.
10.Records of Material /Performance
Test Results :
– The organization shall have records of
material and /or performance test results for
tests specified on the design record or
control plan.
− Material test & Performance Test result shall
indicate and include :
• The design record change level of the parts.
• Engineering change document if the change is not
incorporated in the design record.
• The number ,date ,and change level of the specifications to
which the part was tested.
• The date on which the testing took place.
• The quantity tested.
• The actual results.
• organization name /code.
11.Initial Process Studies :

Acceptance Criteria for Initial Study :

Results Interpretation
Index > 1.67 The process currently meets the
acceptance criteria.

1.33 ≤ Index ≤ 1.67 The process may be acceptable .

Index < 1.33 The process does not currently meet the
acceptance
Criteria.

– The organization shall submit corrective action plan ,if

process capability is not meeting the requirements and shall
start 100 % inspection until the required process capability is
attained .
Process with one sided specifications :

– The organization shall determine with the authorized

customer representative for alternative acceptance criteria .

12.Qualified Laboratory Documentation :

– Qualified Laboratory ( An accredited Laboratory ) .
– Laboratory Scope and Documentation .
– When an External laboratory is used , the organization shall
submit the test results on the laboratory letter head or the
format .The name of the laboratory, date of the tests and the
standards used to run the tests shall be identified.

13.Appearance Approval Report ( AAR) :

14.Sample Production Parts :
– The organization Shall provide the samples as specified by the
customer .

15.Master Sample :
– The organization Shall retain a master sample for the same period
as the PPAP records or as per the customer requirement.
– Master sample shall be identified and shall show customer approval
date on the sample .
– For multi cavity dies , the organization shall retain a master for
each cavity unless otherwise specified by the customer.

16.Checking Aids :
– The organization Shall certify that all aspects of the checking aid
agree with part dimensional requirements.
– Measurement System analysis e.g., gauge R&R ,accuracy, bias,
linearity and stability studies shall be conducted in compliance to
customer requirements.
17.Customer Specific Requirements :
– The organization shall have the records of all customer
specific requirements.

18.Part Submission Warrant ( PSW ) :

– Up on completion of all PPAP requirements , the organization
shall complete the PSW.
− PSW to be signed by Plant Quality In charge of GM level or any other
department person of GM level , Who is representing the customers .
 Submission levels :

– Level 1 : Warrant only .( Low Risk , Minor Change )

– Level 2 : Warrant with product samples and limited
supporting data.
( Medium Risk .Known organization with
good quality record )
– Level 3 : Warrant with product samples and complete
supporting data. ( Default )
– Level 4 : Warrant and other requirements as defined
by the customer. ( In special Condition ).
– Level 5 : Warrant with product samples and complete
supporting data reviewed at the organization
location .( High Risk ,New site or Process ,complex
part , Poor organization performance )
 Retention/Submission Requirements
S.NO REQUIREMENT Level 1 Level 2 Level 3 Level 4 Level 5
1 Design Record R S S * R
− for proprietary components/details R R R * R
− for all other components/details R S S * R
2 Engineering Change document if any R S S * R
3 Customer Engineering approval,if req 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 if applicable 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 Customer Specific Requirements . R R S * R
SPIS-P R R S * R
18 Part Submission Warrant ( PSW) S S S S R
S = The supplier shall submit to the customer and retain a copy of records at appropriate locations.
R = The supplier shall retain at appropriate locations and make available to the customer upon request.
* = The supplier shall retain at appropriate locations and submit to the customer upon request.
 PPAP Approved :
− Approved indicates , that part meets all the specification
requirements of the customer.

 Interim Approval :
− Interim approval permits shipment of material for production
on a limited time or piece quantity basis.

 Interim Approval will only be granted when the

organization has :
• Clearly defined the non-compliances preventing approval.
• Prepared an action plan agreed upon by the customer. PAP
resubmission is required to obtain a status of “Approved ‘’.

Note : The organization is responsible supply only ok parts

during interim approval . period.
− Interim approval will be rejected when :
• Action plan not meeting after expiration date of interim
approval.
• Fails to supply authorized Quantity .

 PPAP Rejected :
− PPAP may be rejected when :
• Failed Production Trail Run .
• PPAP submission does not meet customer requirements based
on the production lot from which it was taken and /or
accompanying documentation. In such cases the submission
and /or process shall be corrected to meet customer
requirements.
.