Production Part Approval Process (PPAP)
Production Part Approval Process (PPAP)
Production Part
Approval Process (PPAP) is a valuable tool for establishing confidence in
component suppliers and their production processes. In today’s competitive
manufacturing environment controlling cost and maintaining a high level of
quality have become vital to a company’s success. Increasing costs of
equipment, materials and labor combined with expanding world markets have
resulted in an increase of outsourced parts. Many component parts are being
outsourced to overseas manufacturers. This often results in longer lead times
and larger order quantities. Therefore it has become imperative to provide
quality parts that meet the customer’s requirements the first time and every time.
Initially PPAP was utilized by the automotive and aerospace industries. PPAP is
now being utilized by several industries to improve communication and provide
quality products. Within the automotive industry the ultimate resource for PPAP
information is the manual published by the Automotive Industry Action Group
(AIAG).
What is Production Part Approval Process (PPAP)
PPAP defines the
approval process for new or revised parts, or parts produced from new or
significantly revised production methods. The PPAP process consists of 18
elements that may be required for approval of production level parts. Not all
of the elements are required for every submission. There are five generally
accepted PPAP submission levels. The PPAP manual contains detailed information,
guidelines and sample documents useful for completing the process requirements.
The resulting PPAP submission provides the evidence that the supplier has met
or exceeded the customer’s requirements and the process is capable of
consistently reproducing quality parts.
Why Perform Production Part Approval Process (PPAP)
The PPAP process
verifies that the supplier understands all customer engineering design
specifications and requirements and that the process is capable of consistently
producing product meeting those requirements during an actual production run at
the quoted production rate. PPAP and other quality tools continue to be
implemented into more industries; therefore it is important to gain an
understanding of the PPAP requirements to remain competitive as a parts
supplier.
When to Perform Production Part Approval Process (PPAP)
A PPAP is required
for any new part submission as well as for approval of any change to an
existing part or process. The customer may request a PPAP at any time during
the product life. This demands that the supplier must maintain a quality system
that develops and documents all of the requirements of a PPAP submission at any
time.
How to Perform Production Part Approval Process (PPAP)
The process of
completing a PPAP submission is fairly complex. This detailed process is a
collection of key elements that must be completed to verify that the production
process will produce a quality product. Not all of the elements are always
required for a PPAP submission. The particular requirements of the PPAP are
usually negotiated during the quoting process.
PPAP Levels of Submission
The PPAP submission
requirements are normally divided into five classifications or levels, as
follows:
·
Level 1 – Part Submission Warrant (PSW) only submitted to the
customer
·
Level 2 – PSW with product samples and limited supporting data
·
Level 3 – PSW with product samples and complete supporting data
·
Level 4 – PSW and other requirements as defined by the customer
·
Level 5 – PSW with product samples and complete supporting data
available for review at the supplier’s manufacturing location
Elements of PPAP
Below is the list
of all 18 elements accompanied by a brief description for each element:
1.
Design Documentation
o
Design documentation shall include both a copy of the customer
and the supplier’s drawings. The documentation should also include a copy of
the purchase order. In some cases the supplier is required to supply
documentation of material composition.
§
The purchase order is used to confirm that the correct part is
being ordered and that it is at the correct revision level.
§
The design engineer is responsible for verifying that the two
drawings match and all critical or key characteristics have been identified.
§
Material composition information is required to supply evidence
that the material used manufacture the parts meets the customer’s specific
requirements.
2.
Engineering Change Documentation
o
If the PPAP is being required due to a request for a change to a
part or product, the documentation requesting and approving the change must be
included in the PPAP package. This documentation usually consists of a copy of
the Engineering Change Notice (ECN), which must be approved by the customer
engineering department.
3.
Customer Engineering Approval
o
When required as part of the PPAP, the supplier must provide
evidence of approval by the customer engineering department.
§
If required, pre-PPAP samples are ordered by the customer for
onsite testing. The samples must be production intent and ship with a waiver so
that testing can be done. When testing is complete, the test engineers will
provide an approval form for inclusion in the PPAP submission.
§
Note: A copy of a “Temporary Deviation” is normally required to
submit parts to the customer prior to a PPAP approval.
4.
Design Failure Mode and Effects Analysis
o
Design Failure Mode and Effects Analysis (DFMEA) is
a cross-functional activity that examines design risk by exploring the possible
failure modes and their effects on the product or customer and their
probability to occur. These failure modes can include:
§
Product malfunctions
§
Reduced performance or product life
§
Safety and Regulatory issues
o
The DFMEA is a living document that should be reviewed and
updated throughout the product life cycle.
5.
Process Flow Diagram
o
The Process Flow Diagram outlines the entire process for
assembling the component or final assembly in a graphical manner. The process
flow includes incoming material, assembly, test, rework and shipping.
6.
Process Failure Mode and Effects Analysis
o
Process Failure Mode and Effects Analysis (PFMEA) reviews
all of the steps in the production process to identify any potential process
quality risk and then document the applied controls. The PFMEA is also a living
document and should be updated even after the product is in normal production.
7.
Control Plan
o
The Control Plan is an output from the
PFMEA. The Control Plan lists all product Special Characteristics and
inspection methods required to deliver products that continually meet the
customer quality requirements.
8.
Measurement System Analysis Studies
o
Measurement System Analysis (MSA) studies
will include Gage Repeatability & Reproducibility (GR&R) studies
on measurement equipment used during assembly or quality control checks.
Calibration records for all gages and measurement equipment must be included.
9.
Dimensional Results
o
Dimensional layout of sample parts is required to validate the
product meets the print specifications. The samples should be randomly selected
from a significant production run usually at least 30 pieces. Each dimension on
the drawing is measured on the final assembly to make sure that it falls within
specification. The results are recorded in a spreadsheet and included within
the PPAP submission.
10. Records of Material
/ Performance Tests
o
This element should contain a copy of the Design
Verification Plan and Report (DVP&R). The DVP&R is a
summary of every validation test performed on the part. It should list each and
every test performed, a description of how the test was performed, and the
results of each test.
o
This section may also include copies of all the certification
documents for all materials (steel, plastics, etc.) listed on the prints. The
material certification shall show compliance to the specific call on the print.
11. Initial Process
Studies
o
Initial process studies will be done on all the production
processes and will include Statistical Process Control (SPC) charts
on the critical characteristics of the product. These studies demonstrate that
the critical processes are stable, demonstrate normal variation and are running
near the intended nominal value.
12. Qualified
Laboratory Documentation
o
Qualified laboratory documentation consists of the industry
certifications for any lab that was involved in completing validation testing.
This could be for an in-house test lab or any offsite contracted test
facilities that were used for validation or material certification testing.
13. Appearance Approval
Report
o
The Appearance Approval Inspection (AAI) is applicable for
components affecting appearance only. This report verifies that the customer
has inspected the final product and it meets all the required appearance
specifications for the design. The appearance requirements could include
information regarding the color, textures, etc.
14. Sample Production
Parts
o
Sample production parts are sent to the customer for approval
and are typically stored at either the customer or supplier’s site after the
product development is complete. A picture of the production parts is usually
included in the PPAP documentation along with documentation regarding the
location that the parts are being stored.
15. Master Sample
o
A master sample is a final sample of the product that is
inspected and signed off by the customer. The master sample part is used to
train operators and serves as a benchmark for comparison to standard production
parts if any part quality questions arise.
16. Checking Aids
o
This is a detailed list of checking aids used by production. It
should include all tools used to inspect, test or measure parts during the
assembly process. The list should describe the tool and have the calibration
schedule for the tool. Checking aids may include check fixtures, contour,
variable and attribute gages, models or templates.
o
MSA may be required for all checking aids based on customer
requirements.
17. Customer Specific
Requirements
o
This element of the submission package is where any special
customer requirements are contained. For bulk materials, the customer specific
requirements shall be recorded on the “Bulk Material Requirements Checklist”.
18. Part Submission
Warrant
o
The Part Submission Warrant (PSW) form is a summary of the
entire PPAP submission. A PSW is required for each of part number unless
otherwise stated by the customer. The PSW includes:
§
The reason for submission (design change, annual re-validation,
etc.)
§
The level of documents submitted to the customer
§
Declaration of part conformity to customer requirements
§
A section provided for any required explanation or comments
§
Supplier authorized person signature along with contact
information
§
An area for the customer to indicate disposition of the PPAP
The PPAP process is
a detailed and lengthy process. The PPAP package includes documentation of
various multiple cross-functional tools and documents the ability of the
supplier to meet all customer requirements. PPAP provides customers adequate
information to validate that all areas of the design and production processes
have been reviewed thoroughly to ensure that only high quality products will be
allowed to ship to the end customer.
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