Production Part Approval Process (PPAP) is a set of compiled documents on product (part) quality and process performance results. PPAP is to be compiled by an automotive manufacturer (supplier)as evidence of its product and manufacturing capabilities to produce product for an automotive customer. It forms part of a automotive supplier qualification process.
The reason for this is to:
- Ensure that the supplier understands the customer’s product and process requirements,
- To show that the supplier has the knowledge and capabilities to manufacture the automotive part,
- As qualification evidence records for the qualification process or any product change.
Below are some basic steps taken in preparing PPAP for submission to an automotive customer;
- Obtain the Customer Specific Requirements (CSR) from customer. CSR can be obtained from the automotive customer together with the part/product/material specifications. These may include all the PPAP forms that are to be used to record PPAP data requirements. OEM and large automotive companies provide these on their websites. The Part Submission Warrant (PSW) form will be provided by the automotive customer. At times the standard/common PSW form is used.
- Determine the PPAP Submission Level You Required To Submit To. There are 18 PPAP submission requirements listed. Depending on the Submission Level, documents will have to be:
– Submitted to the customer and copies retained at supplier’s locations
-Retained at supplier’s locations and made accessible for customer’s viewing upon request.
-Retained at supplier’s locations and submitted upon request.
- Plan out where and how these PPAP records data are to be collected/recorded. Use the APQP Manual as a guideline to understand and determine how and where in the manufacturing process these PPAP data requirements are to be collected while the Qualification Production Runs are being done. It is important to know what the sample size is and number of qualification runs are required by the automotive customer for the PPAP data requirements. (The automotive customer is likely to issue a purchase order for these parts if they are reasonably large quantities).
- Compile the standard and the available records. It is best to begin compiling the available ready available documentations for the PPAP. Such as the Product Specifications, Product Drawings, Product Manuals, Product Manufacturing Process Flow Maps, Product and Process Control Plans, Design FMEA, Process FMEA and the PSW.
- Plan & Perform Qualification Production Runs. Ensure that the appropriate Control Charts are ready to be used to capture data of the production parameters and part dimensions before the Qualification Production Run begin. Review the use of the PFMEA and Control Plans during the Qualification Production Runs. Revise and update the PFMEA and Control Plans as and when it is required. Perform visual inspection on part as required and record data.
- After Completing Each Qualification Production Run. Measure the critical and important part dimensions as specified by the automotive customers. Perform the any other product testing, destructible, on the part as specified by the automotive customer. Record these measurement data on the specific forms. (Specific forms are provided by the automotive customer, if not use on format). Perform a Gage Repeatability & Reproducibility (MSA) analysis on the data using the actual QC inspectors. Complete the Appearance Approval Report (AAR). Calculate the Initial Process Capability Study. (Pp/Ppk)
- Put Together Information & Product Samples, Master Samples, Checking Aids. Final stage is to compile all the document records listed in the PPAP and determine which documents are to be submitted in a compiled PPAP Folder to the automotive customer. This is be based on the PPAP Level that the customer had requested. Master Samples and Checking Aids are to be maintained appropriately at location.
- Complete PSW & Bind. Accurately complete the PSW and signed it. Professionally bind all documents together into a folder for submission attaching PSW at the front after a content page.