PPAP Guide
Production Part Approval Process documentation.
What is PPAP?
PPAP (Production Part Approval Process) is a standardized process in the automotive and manufacturing industries used to establish confidence in suppliers and their production processes.
Purpose of PPAP
- Verify that suppliers understand customer requirements
- Demonstrate that production processes can consistently produce parts meeting specifications
- Provide documented evidence of process capability
- Establish a baseline for ongoing quality management
When is PPAP Required?
- New Part: First production of a new part or product
- Engineering Change: Design or specification changes
- Tooling: New or modified tooling, dies, molds, patterns
- Process Change: Changes to manufacturing methods or locations
- Material Change: New or different materials or sub-suppliers
- Re-qualification: Periodic revalidation as requested by customer
PPAP Submission Levels
PPAP defines five submission levels that determine what documentation must be provided to the customer.
| Level | Description | Requirements |
|---|---|---|
| Level 1 | Part Submission Warrant (PSW) only | Only the PSW is submitted to the customer. Supplier retains all other documentation. |
| Level 2 | PSW with product samples and limited data | PSW, product samples, and limited supporting data submitted. |
| Level 3 | PSW with product samples and complete data | Default level. Complete supporting data package submitted with PSW and samples. |
| Level 4 | PSW and other requirements as defined by customer | Customer-specific requirements beyond standard elements. |
| Level 5 | PSW with product samples and complete data at supplier location | Complete data package available for review at supplier's manufacturing site. |
The 18 PPAP Elements
PPAP consists of 18 elements that may be required depending on the submission level and customer requirements.
Design & Planning Elements
- Design Records - Engineering drawings, CAD data, specifications
- Engineering Change Documents - Approved change notices
- Customer Engineering Approval - When required by customer
- Design FMEA - Design Failure Mode and Effects Analysis
- Process Flow Diagrams - Manufacturing process flow
- Process FMEA - Process Failure Mode and Effects Analysis
- Control Plan - Document describing manufacturing controls
Measurement & Analysis Elements
- MSA Studies - Measurement System Analysis (Gage R&R)
- Dimensional Results - Layout inspection results
- Material/Performance Test Results - Lab test reports
- Initial Process Studies - Cpk/Ppk capability studies
- Qualified Laboratory Documentation - Lab accreditation
- Appearance Approval Report (AAR) - For visual/cosmetic parts
Sample & Validation Elements
- Sample Production Parts - Physical samples from production run
- Master Sample - Retained reference sample
- Checking Aids - Gages, fixtures, templates used
- Customer-Specific Requirements - Additional customer needs
Approval Element
- Part Submission Warrant (PSW) - Formal approval document summarizing PPAP package
Creating a PPAP in Buttress QMS
Step-by-Step Guide
Step 1: Navigate to PPAP
Click PPAP in the left sidebar, then click + New PPAP
Step 2: Enter Basic Information
- PPAP Number: Auto-generated or custom identifier
- Supplier: Select the supplier submitting the PPAP
- Part: Select or enter the part being approved
- Submission Level: Choose Level 1-5 (default is Level 3)
- Reason: New part, engineering change, process change, etc.
Step 3: Track Elements
For each of the 18 elements, indicate:
- Not Required - Element not applicable
- Pending - Element required but not yet complete
- Submitted - Element submitted for review
- Approved - Element approved
- Rejected - Element needs rework
Step 4: Upload Documents
Attach supporting documents (drawings, test reports, FMEA, control plans, etc.) to each element.
Step 5: Submit for Review
Once all required elements are complete, submit the PPAP for approval.
PPAP Workflow
PPAP Status Flow
Initial creation
Sent to customer
Customer reviewing
Full approval
PPAP Disposition Options
Approved
Part and process meet all requirements. Production may proceed.
Interim Approval
Temporary approval with conditions. Supplier must complete open items by specified date.
Rejected
PPAP does not meet requirements. Supplier must correct issues and resubmit.
Control Plans
A Control Plan is a written description of the systems used to control parts and processes during manufacturing.
Control Plan Phases
Prototype
Description of dimensional measurements and material/functional tests during prototype build.
Pre-Launch
Enhanced controls during pre-production trial runs. Includes additional inspections and process monitoring.
Production
Ongoing controls for full production. Documents characteristics, specifications, and control methods.
Control Plan Contents
- Process Step: Operation name and number
- Characteristic: Product or process characteristic being controlled
- Specification: Engineering tolerance or requirement
- Evaluation Method: Gage, measurement technique
- Sample Size & Frequency: How often to measure
- Control Method: SPC chart, go/no-go, visual inspection
- Reaction Plan: What to do if out of specification
Part Submission Warrant (PSW)
The PSW is the summary document of the entire PPAP package and is required at all submission levels.
PSW Contents
- Part Information: Part number, name, revision level
- Customer Information: Customer name, buyer code, application
- Supplier Information: Supplier name, code, manufacturing location
- Submission Reason: New part, change, requalification
- Submission Level: Level 1-5
- Element Checklist: Status of all 18 elements
- Material Reporting: IMDS requirements (automotive)
- Authorized Signatures: Supplier and customer approvals
Generating PSW in Buttress QMS
- Navigate to the PPAP detail page
- Ensure all required elements are complete
- Click Generate PSW
- Review the pre-filled information
- Add any required comments or notes
- Download as PDF for customer submission
PPAP Best Practices
Do:
- Start PPAP planning early in the project
- Clarify customer requirements upfront
- Complete capability studies with production tooling
- Document all deviations and get customer approval
- Keep original documents for audit trail
- Track PPAP due dates and follow up
Don't:
- Submit incomplete packages
- Use prototype samples for production PPAP
- Skip process capability studies
- Ignore customer-specific requirements
- Assume submission level without confirmation
- Ship production parts before PPAP approval
Common PPAP Rejections
- Missing Elements: Required elements not submitted
- Incomplete Data: Test results or dimensions not complete
- Low Capability: Cpk/Ppk below customer requirements
- MSA Failures: Measurement system not adequate
- Unsigned PSW: Missing authorized signatures