PPAP - Prototype vs. Production



I need to know next;
On my company there is an approval process for new products but samples are made in a Router Machine before we ask for new mold.
I think is understandable If we don’t know if some client will accept our product we won’t ask for a new mold to run a little quantity in a pilot run of our client.
Look If I have to do PPAP requirements (Level 3) and we need to do Measurement System Analysis Studies
Do you think If necessary to take measurements of Router Machine Samples or we must to wait to do a Run with a New Mold to take these ones.
Or I must to take both?
Please tell me What do you think?

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Howard Atkins

Forum Administrator
Staff member
If I understand correctly you are making a prototype.
There are different procedures for approval of prototypes, after you have this approval then you can build a mold and submit for approval.
PPAP approval must be on production tools and as per the production process.
If you one of your question is whether you need to carryout statistical studies for prototyping activity that you carryout, then the answer is NO.

Al Dyer

How about this,

Do Both, what harm is there in monitoring your processes at all stages with the expectation that your studies will ease the requirements of further studies and give you the piece of mind you so assuridly deserve!

Howard Atkins

Forum Administrator
Staff member
I agree with Al if you are talking about Gauge R&R, this tends to be the most ignored part of the system.
Capability studies on prototypes will not really give you anything as they will not represent the final parts.


It depends on the customer of course. Some customers do require short run capability or layout inspections of prototype parts.

Al Dyer

Very true Howard,

In my experience with automotive their quest is the bottom line. They don't want to see a Cpk or R&R on your prototypes or "attempts", they are looking for the bottom line which is what can we expect in the plant.

Now, if that is screwed up they might start backtracking to find out why your APQP (FMEA) system did not pick up the low performance or failure.
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