PPAP: Product Part Approval Process and Digital PPAP
This article provides you with a comprehensive overview of the PPAP process as well as verification and application in practice and what is meant by "Digital PPAP". On the one hand, it is a necessary tool for OEM manufacturers to create confidence in product suppliers and their production processes. It is part of the product development process. On the other hand, PPAP aims to reduce the risks prior to the release of a product or service in a formal and team-oriented manner using established tools and techniques.
Overview Classification of PPAP
The basics of PPAP
PPAP is the verification and approval process for production parts. It contains the basic requirements for the sampling of all production and spare parts and corresponds to the corresponds to the Production Process And Product Approval (PPA, also abbreviated PPF). While PPA is implemented according to the specifications of the German Association of the Automotive Industry (VDA Volume 2), PPAP is based on the American Automotive Industry Action Group (AIAG) for supplier quality requirements. It consists of 5 levels and 18 unique elements that help build confidence in a supplier's production processes and overall product quality.
Logically, the PPAP process is used mainly in the automotive industry based on the industry standards IATF 16949:2016 and ISO 9001:2015. It was originally developed by the AlAG in 1993 in collaboration with the "Big 3", Ford, Chrysler and GM. The latest version of PPAP is the 4th edition from the AlAG, which came into force on June 1, 2006.
In addition to PPAP, there is also the FAI (First Article Inspection) procedure. When is a PPAP performed vs. when is an FAI performed?
Are both performed at the supplier site or where are they performed and who is responsible (for both PPAP and FAI)?
Do we consider only the CTQ dimensions on the drawing or all dimensions (for PPAP and FAI)?
What if a particular CTQ dimension does not meet the requirement (for both PPAP and FAI). What are the necessary actions?
What happens if a specific non-CTQ dimension does not meet the requirement (for both PPAP and FAI). What are the necessary actions?
Is there a sample size for the lot on which PPAP and/or FAI will be performed?
All relevant standards specifically for the aerospace industry (for PPAP and FAI)
However, PPAP has now also become established far beyond the automotive industry in many different sectors, such as the electrical industry (mostly along IATF 16949:2016), shipbuilding (ISO 30005:2012) or aerospace and defense (sampling, DIN EN 9102).
When is PPAP required?
Reasons for PPAP
If an OEM requires it. The OEM can request it at any time. In the modern automotive industry PPAP is considered mandatory. Here are some examples of when PPAP would be required:
New supplier: The OEM requires the new supplier to use PPAP to go through the same standardized approval process that its predecessor had to go through.
Development of new parts: Here, all 18 requirements of the PPAP template normally must be met.
Design or process changes: The PPAP addresses the proper approval of these changes prior to next stage assembly/process.
Technical changes: Technical change and Process Failure Mode and Effects Analysis (PFMEA) documents are particularly important to minimize risks.
Lack of compatibility on previous submissions and need for corrections: Full documentation of corrective actions (and deviation measurements) allows the tracking of all errors on their design inputs and corrective actions, as well as avoidance of the problem on the next submission.
Start of production at a new location: The PPAP ensures that the right information and data are available to maintain part conformity during the changeover.
To document the use of appropriate tools and measuring equipment (transfer, replacement, refurbishment or additional tools and measuring equipment).
What are the 5 submission levels of the PPAP - Part Submission Warrant (PSW)?
This is the scope agreement. They are a kind of "container" for the different requirements.
The 5 levels differ in the scope of sampling:
Part Submission Warrant (PSW) ...
PSW is only submitted to the customer.
with sample parts and limited supporting data.
with sample parts and comprehensive supporting data.
and other requirements as determined by the customer.
with sample parts and complete supporting data that is available at the supplier's production site for evaluation
What are the 18 elements and requirements of PPAP?
In the submission stages, associated requirements from this list are applied in each case.
Note: Each stage requires a complete APQP according to the customer's requirements. The PPAP level only indicates which elements you submit and which you keep at your site.
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This usually in the form of a CAD model (2D or 3D) created either by the customer and delivered with the purchase order (PO) or by the supplier.
If the supplier is responsible for the design, this usually is in the form of a released drawing in the supplier's release system.
It is often necessary to demonstrate where the design records, such as CAD/CAM calculation data, part drawings, or specifications exist in an electronic data format, such as computer-based data exist.
There are cases today where a printout is still required to show which measurements are to be take.
As part of the design record, some OEMs also reference other related documents that are part of the design record.
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The supplier must be able to provide written evidence of all agreed design changes that have not yet been incorporated into the design documents but have already been incorporated into the product, part or tool.
These documents are also abbreviated
ECN.
For this purpose, call logs, telephone notes with records of who took part in the call, call data and clear reference to the part number are often also used.
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The customer receives sample parts, which are made available to him in advance so that he can carry out his first tests. This is done before the PPAP is created. It is possible that the customer will need additional technical approvals.
This is often called "Customer Engineering Approval" in the requirements.
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This is a copy of the DFMEA that has been reviewed and approved by the supplier and customer.
The designer is responsible for (DEMEA)
This only applies if the supplier is responsible for the design.
The DFMEA is the application of the principles of "Failure Mode and Effects Analysis" (FEMA), but specifically focused on the design phase of the process.
The basic concept of DFMEA is to understand where the product design might fail. The DFMEA method allows the design team to document what they know and suspect about a product's failure modes before the design is finalized and then use this information to eliminate or mitigate the failure modes. Ideally, DFMEA is used in the earliest stages of concept development and can then help weed out competing designs and develop new, more robust concepts.
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The supplier must be able to present a process flow diagram (PFD) created in the supplier-specific format. This must describe, to an appropriate extent, all steps and the sequence of the process.
Detailed information is provided in the QS9000 "Advanced Product Quality Planning (APQP)" reference manual.
Process flow diagrams for "product families" of similar parts are acceptable if the new parts have been tested for compliance.
A process flow diagram includes, among other things, process steps, test steps, transport, intermediate and final storage.
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Process FMEA, or "Process Failure Mode and Effects Analysis," follows the steps of the flowchart and indicates what could go wrong during the operation and assembly of each component until the product is shipped.
The Process FMEA builds on the design FMEA.
A Process FMEA should be started with a manufacturing flow chart. This lists all product features that are manufactured in the individual operations. Finding the consequences of possible defects and assessing the significance of defects can be viewed in the corresponding design FMEA or system FMEA, if required.
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The Control Plan (measurement log results) follows the PFMEA steps and provides additional details on how the potential problems are checked for in the incoming quality and assembly process or during the inspections of the finished products even up to the delivered final product.
The supplier shall provide evidence that verifications of measurements have been performed in accordance with the requirements of the design records and the control plan and shall demonstrate that the results are in accordance with the specified requirements.
Forms such as Measurement Report Annex 2 (VDA) or "Dimensional Results" (QS9000) are often used for this purpose.
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The MSA usually includes the Gage R&R study for critical or particularly important features.
It confirms that the measurement system (an instrument and an evaluator) can measure these characteristics of the product.
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A list of all dimensions noted on the ballooned drawing.
This list shows the product feature, specification, measurement results, and whether this dimension is "ok" or "not ok".
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A summary of all tests performed on the part.
This summary is usually in the form of a so-called DVP&R (Design Verification Plan & Report) which lists each individual test, when it was performed, the specification, the results and the pass/fail rating.
The DVP&R is reviewed and signed off by both customers and suppliers.
In addition, this section lists all material certifications (steel, plastics, coatings, etc.) as indicated on the print.
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As a rule, this section displays all Statistical Process Control (SPC) charts that affect the most critical features.
This is to demonstrate that critical processes have stable variability and run near the intended nominal value.
The Initial Process Study is also referred to as a process capability study.
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Copy of all laboratory certificates from the laboratories that performed the reported tests.
Also required are all calibration certificates for all measuring instruments and test equipment.
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A copy of the Appearance Approval Inspection (AAI) form signed by the customer.
Applies only to components that affect the appearance and are required by the customer.
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A sample from the first production series.
The PPAP package usually has a picture of the sample and indicates where it is stored.
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A sample signed off by the customer and supplier, usually used to train operators for subjective inspections.
The master sample should be replaced at regular intervals and approved by the customer at specified times.
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For special part inspection tools, this section includes a picture of the tool and calibration records, including a dimensional report of the tool.
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Each customer may have specific requirements that must be included in the PPAP.
In general, it should be the length, width, height, weight, area density or other technical value that depends on the product.
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Here, the entire PPAP is summarized.
It includes the reason for submission (design change, annual revalidation, etc.) and shows the scope of data/documents submitted to the customer.
This also includes the results of the inputs to all drawing and specification requirements.
PPAP Approval Status:
Approved/Released
"The part meets all the requirements of the customer" and "The supplier is entitled to supply production quantities of the part".
Provisionally Approved/Conditional Release
This allows the part to be shipped on a limited time or quantity basis. The causes of failure must be identified, the action plan must be submitted to the OEM and the new sampling must be performed.
Rejected
The part does not meet the customer's requirements, the causes of failure must be identified, the action plan must be submitted to the OEM and the new sampling must be carried out.
What are the advantages of using PPAP?
In short, PPAP minimizes the risk that something will go wrong and corrective actions will have to be taken. A thorough evaluation of production processes, including speed and quality performance, prevents parts shortages and quality problems. In the end, this benefits both suppliers and OEMs. It enables a smooth launch of new products that everyone who is involved in can be proud of.
The evidence and the evidence process help maintain design integrity
The early identification of problems that need to be solved
PPAP reduces warranty costs and prevents the cost of poor quality,
Assists in managing supplier changes, prevents the use of unapproved and non-conforming parts, identifies suppliers that need more development, and improves overall product quality and customer satisfaction
How much effort is required for PPAP?
The application of PPAP can be a very reliable tool, unless many PPAP processes are still done manually (documents not machine-readable as pdf, Excel, communication via e-mail). Then the effort for organization and documentation of the PPAP process increases and it can lead to delays in the delivery of technical parts or to defective parts still being produced at the start of production.
What does this mean?
In many cases, suppliers have to create internal documents or laboriously search for templates that are then outdated or incomplete. Furthermore, a filing system is often set up to enable collaboration within the company and to maintain an overview. Software is often used here that is intended to facilitate collaboration with documents (e.g. Sharepoint, Excel, Word, pdf ...) but ultimately leads to data silos.
When an OEM requests documents from its suppliers, it expects a quick response. The supplier's response time can determine whether he selects him or commissions another supplier. Or if, for example, the OEM's quality management team wants to see the supplier's PPAP documentation, the supplier may have to laboriously gather everything together. This increases the likelihood that something will be criticized. The supplier could even be reprimanded for poor quality management. Ideally, suppliers have all the important data at their fingertips at all times and are perceived positively from the outset.
The effort can be reduced by a cloud-based platform if OEMs and ideally all suppliers in the entire supply chain use the platform together. The cost reduction can be enormous for everyone involved - with greatly increased transparency, which leads to fewer errors.
Example of reducing effort through PPAP digitalization with a supply chain collaboration platform - in this case material.one. Excerpt from the study report "The potential of digitalized sampling"
Conclusion:
PPAP is a necessary tool for OEM manufacturers to build confidence in product suppliers and their production processes and to reduce risks. It is important to support communication between suppliers and OEMs and to achieve high production part quality. It is needed in various situations, such as new supplier introduction, new part development, or design and process changes.
The chief benefits of using PPAP are minimizing risks and avoiding quality problems. It helps maintain design integrity, reduces warranty costs, and improves customer satisfaction. However, the effort required for PPAP can be high, especially if the processes are still performed manually. Digitizing the PPAP process can reduce the effort and improve collaboration between suppliers and OEMs.
One use case for the digital implementation of the PPAP process with a cross-platform "Supply Chain Collaboration Platform" is the use of the material.one platform at Mercedes-Benz Cars. This platform serves as a central link between suppliers, sub-suppliers, laboratories and Mercedes-Benz for the digitalization of material sampling. In addition, the study report "The potential of digitalized sampling" is available here"
Use Case - Digital PPAP Material at Mercedes-Benz
The digitalization of the material sampling process through material.one, a cross-platform "Supply Chain Collaboration Platform" in the example of Mercedes-Benz Cars. The platform serves as a central link between all parties involved: suppliers, sub-suppliers, laboratories and Mercedes-Benz.
Click here for the Mercedes-Benz Use Case article: Learn more
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