Production Part Approval Process (PPAP)

Updated: Sep 11

The Production Part Approval Process (PPAP) 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.


The Production Part Approval Process (PPAP) provides customers with evidence that: a) Component suppliers have understood their requirements; b) The product meets the customer's requirements; c) The production process is capable of consistently producing the conforming product. The PPAP process is currently governed by the PPAP manual published by the Automotive Industry Action Group (AIAG).


When PPAP Required?

  • New part

  • Engineering Change

  • Tooling: Transfer, replacement, addition,

  • Correction of Discrepancy

  • Tooling inactive > 1 year

  • Sub Supplier or material Source change

  • Change in part processing

  • Part produce at new or additional location

"PPAP is required with any significant Change to product or process"


Benefits of PPAP Submission

  • Help to maintain design integrity

  • Identify issues early for resolution

  • Reduce warranty charges and prevents the cost of poor Quality

  • Assist with managing supplier changes

  • Prevent the use of the unapproved and non-conforming product

  • Identify supplier that need more improvement

  • Improve the overall Quality of Product and Customer satisfaction

PPAP process Requirments

1- Significant Production Run

For the production part, the product for PPAP shall be taken from a Significant Production Run. This Significant Production Run shall be from one hour to eight hours of production, and with the specific production quantity to total a minimum of 300 consecutive parts unless otherwise specified by the authorized customer representative.

Significant Production Run shall be conducted at the production site, at the production rate using the production tooling, production gauging, production process, production materials, and production operators. Part from each unique production process eg. duplicate assembly line and or work cell each position of multiple cavities die, mold, tool, or pattern, shall be measured and representative parts tested.


2-PPAP Requirements

Production parts shall meet all customer engineering design record and specification requirements (including safety and regularity requirement)

Specified PPAP Requirments listed below


1-Design Records

2. Authorized Engineering Change Documents

3. Customer Engineering Approval, if required

4. Design Failure Modes and Effects Analysis (DFMEA), applied in special situations

5. Process Flow Diagram

6. Process Failure Modes and Effects Analysis (PFMEA)

7. Control Plan

8. Measurement System Analysis (MSA)

9. Dimensional Results

10. Records of Material / Performance Test Results

11. Initial Process Studies

12. Qualified 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)


PPAP Submission levels

Retention/Submision requirments

Organization Shall use level 3 as the default level for the submission unless otherwise

specified by the authorized customer representative.


1. Design Records

A copy of the drawing. If the customer is responsible for designing, this is a copy of the customer drawing that is sent together with the Purchase Order (PO). If the supplier is responsible for designing this is a released drawing in the supplier’s release system.

2. Authorized Engineering Change Documents

A document that shows the detailed description of the change. Usually, this document is called “Engineering Change Notice”, but it may be covered by the customer PO or any other engineering authorization.

3. Customer Engineering Approval, if required

This approval is usually the Engineering trial with production parts performed at the customer plant. A “temporary deviation” usually is required to send parts to customers before PPAP. Customers may require other “Engineering Approvals”.

4. Design Failure Modes and Effects Analysis (DFMEA), applied in special situations

A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed-off by supplier and customer.

5. Process Flow Diagram

A copy of the Process Flow, indicating all steps and sequences in the process, including incoming components.

6. Process Failure Modes and Effects Analysis (PFMEA)

A copy of the Process Failure Mode and Effect Analyis (PFMEA), reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and indicate “what could go wrong” during the fabrication and assembly of each component.

7. Control Plan

A copy of the Control Plan reviewed and signed-off by supplier and customer. The Control Plan follows the PFMEA steps and provides more details on how the “potential issues” are checked in the incoming quality, assembly process or during inspections of finished products.

8. Measurement System Analysis (MSA)

MSA usually contains the Gage R&R for the critical or high impact characteristics, and a confirmation that gauges used to measure these characteristics are calibrated.

9. Dimensional Results

A list of every dimension noted on the ballooned drawing. This list shows the product characteristic, specification, the measurement results, and the assessment showing if this dimension is “ok” or “not ok”. Usually, a minimum of 6 pieces is reported per product/process combination.

10. Records of Material / Performance Test Results

A summary of every test performed on the part. This summary is usually on a form of DVP&R (Design Verification Plan and Report), which lists each individual test, when it was performed, the specification, results and the assessment pass/fail. If there is an Engineering Specification, usually it is noted on the print. The DVP&R shall be reviewed and signed off by both customer and supplier engineering groups. The quality engineer will look for a customer signature on this document. In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print. The material certification shall show compliance to the specific call on the print.

11. Initial Process Studies

Usually, this section shows all Statistical Process Control charts affecting the most critical characteristics. The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value.

12. Qualified Laboratory Documentation

Copy of all laboratory certifications of the laboratories that performed the tests reported in section 10.

13. Appearance Approval Report (AAR)

A copy of the AAI (Appearance Approval Inspection) form signed by the customer. Applicable for components affecting appearance only.

14. Sample Production Parts

A sample from the same lot of initial production run. The PPAP package usually shows a picture of the sample and where it is kept (customer or supplier).

15. Master Sample

A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections.

16. Checking Aids

When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including the dimensional reports of the tool.

17. Customer-Specific Requirements

Each customer may have specific requirements to be included on the PPAP package. North America auto makers OEM (Original Equipment Manufacturer) requirements are listed on the IATF website.

18. Part Submission Warrant (PSW)

This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for “results meeting all drawing and specification requirements: yes/no” .


AIAG Production Part Approval process PPAP 4th Edition- Click here