PPAP Documents List

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PPAP Documents List

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 PPAP requires the manufacture of a sample number of parts on actual production tooling, using the same procedures, personnel, production facility, and all other aspects of the expected production run. This sampling is of some finite number, usually something like 300 pieces.

The PPAP Documents List

  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 a 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 the customer 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 fabrication process, including incoming components.
  6. Process Failure Modes and Effects Analysis (PFMEA)
    A copy of the Process Failure Mode and Effect Analysis (PFMEA), reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps and indicates “what could go wrong” during the fabrication and assembly of each component.
  7. Control Plan
    A copy of the Control Plan was 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, specifications, 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 on section 10.
  13. Appearance Approval Report (AAR)
    A copy of the AAI (Appearance Approval Inspection) form was 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 customers and suppliers 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 report of the tool.
  17. Customer-Specific Requirements
    Each customer may have specific requirements to be included in the PPAP package. North America automaker’s 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” refers to the whole package.

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PPAP Documents List

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