What is PPAP Documentation?

In today’s era in an Automobile/Aerospace Industry, every supplier has to be assessed of his capabilities on the way he carries out his work. He is required to provide proof of how each process functions and its difficulties as documented evidence to its client for verification to ensure long-term business. That’s why the term Production Part Approval Process (PPAP) Document came into existence. Every OEM’s goal is to have a trustworthy/reliable supplier and PPAP enforces that requirement.

Due to its positive results, other industries like defense, consumer goods, medical, electronics have been quick to adopt PPAP.

This in-depth document is like a formal certification/approval by the supplier that quality is being taken the utmost care and any kind of defects is being avoided.

PPAP is important for –

• The OEM’s to validate supplier’s performance based on quality, quantity and its effectiveness under a production process.
• The suppliers, as they would know what are the customers (OEM) requirement and specifications for a product.
• Both the customer and the supplier to maintain a perfect document on all the necessary information on a part which can be referred anytime.

When PPAP is required?

PPAP is mostly required when a change to an existing part or process is being planned or initiated, new parts, etc. Whenever such a change takes place, it is considered a critical activity for an Automobile/Aerospace Industry. To address such change, PPAP is considered a valuable tool for establishing confidence in component suppliers and their production process.

What are the Required PPAP Documents?

Automotive Section

1. Design records
2. Engineering Change Documents
3. Customer Engineering Approval
4. Design Failure Mode and Effects Analysis (DFMEA)
5. Process Flow Diagrams
6. Process Failure Mode and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement System Analysis (MSA) Studies
9. Dimensional Results
10. Material Performance Test Results
11. Statistical Process Control (SPC)
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Product (Drawing)
15. Master Sample
16. Checking Aids
17. Records of Compliance with Customer-Specific Requirements
18. Part Submission Warrant (PSW)

Aerospace Section

1. Released Production Drawings or Definition
2. Supplementary Product Requirement Documents
3. Production Purchase Order
4. Design Failure Mode and Effects Analysis (DFMEA)
5. Process Flow Diagram
6. Process Failure Mode and Effects Analysis (PFMEA)
7. Process Control Plan
8. Process Readiness Study
9. Initial Process Studies
10. Measurement System Analysis
11. Engineering Frozen Planning/Engineering Source Approval
12. Dimensional Reports
13. Functional Testing Approval
14. Special Process Approval & NDT
15. Material Certification Documentation
16. Raw Material Approval
17. Part Marking Approval
18. Packaging, Preservation and Labelling Approval
19. Review and Sign-Off

Note – The requirement for the number of documents can vary as per the OEM needs.

PQSmitra’s PPAP Consulting Services

PPAP being a lengthy and detailed process, each document has its own significance and importance. So for performing at a top-level we have helped clients to effectively go through the required PPAP documents and identify non-conformances.

Our gap analysis has proved to meet compliances with the PPAP requirements and also bring in sustainable changes.