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1. Design Records: A copy of the drawing or model provided by customer.
2. Engineering Change Documents: Detailed description of changes of parts from previous revisions called Engineering Change Notice.
3. Customer Engineering Approval: Customer approval of sample production parts.
4. Design Failure Mode and Effects Analysis (DFMEA): Prediction of a product's potential design failure.
5. Process Flow Diagrams: All steps in manufacturing process including components, measurement, and inspection.
6. Process Failure Mode and Effects Analysis (PFMEA): Prediction of a potential process failure that could occur during production.
7. Control Plan: Details the plan for how quality will be implemented to ensure a stable and reliable process.
8. Measurement System Analysis (MSA): Conformance to customer’s ISO or TS standard. Usually Gage R&R for critical impact characteristics to control repeatability and reproducibility and confirmation that gages are calibrated to measure these characteristics to control measurement bias.
9. Dimensional Results: A list of every dimension noted on the ballooned drawing or model with pass/fail assessment.
10. Material / Performance Test Results: Summary of every test performed on the part, usually in the form of DVP&R (Design Verification Plan and Report).
11. Initial Process Studies: Shows that critical processes are reliable. Includes SPC (statistical process control) charts.
12. Qualified Laboratory Documentation: All industry certifications for validation testing.
13. Appearance Approval Report (AAR): Customer approval on final product appearance including color, texture, fit, and more.
14. Sample Product: Sample from initial production run.
15. Master Sample: Sample part signed off by customer and supplier.
16. Checking Aids: Detailed list of all tools used to inspect and measure parts.
17. Records of Compliance with Customer-Specific Requirements: List of customer’s specific requirements for PPAP process.
18. Part Submission Warrant (PSW): Summary of entire PPAP submission.

1. Validating supplier’s ability. Ability to meet customer and regulatory requirements.
2. Understanding customer requirements.
3. Establishing a reliable and repeatable process that won’t change without further customer approval.
4. Reducing cost and having faster time to market.
5. Maintaining expectations & compliance on both sides.

PPAP is typically required when:

1. A new part or product.
2. Product changes/corrections: design, materials, supply, and function.
3. Process changes/corrections: method, tools, location, and inspection criteria.
4. Inactive tooling for more than one year.

PPAP 5 Levels of Submission:

The PPAP report has 5 levels of submissions with Level 3 as the default level of PPAP submission approval.

1. Level 1: Part Submission Warrant (PSW) only submitted to the customer.
2. Level 2: PSW with product samples and limited supporting data.
3. Level 3: PSW with product samples and complete supporting data.
4. Level 4: PSW and other requirements as defined by the customer.
5. Level 5: PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location.