What is PPAP (Production Part Approval Process)?

harley123

Starting to get Involved
#1
Hi all,

I have a customer who is requiring PPAP.

I am not sure what this is. They are the first to require this.
Can someone explain what this is?

I know what the letters stand for but what should be included in the process?


Thanks
 

Miner

Forum Moderator
Staff member
Super Moderator
#2
Is this an automotive customer? If so, they probably expect the PPAP process laid out in the PPAP manual available from AIAG.

However, there are many non-automotive customers that have either heard about PPAP, or have managers that have come from automotive that also request a PPAP from suppliers. These customers often have a much different concept of what a PPAP is. They often want part, but not all of the automotive PPAP. The only way to know for certain is to ask the customer in question what the specific requirements are.
 

ScottK

Not out of the crisis
Staff member
Super Moderator
#4
I've worked with a number of Medical Device companies that have made their own version of PPAP. Especially Stryker - they called it SPPAP (supplier production part approval process)

I would first ask for a copy of their PPAP procedure and forms and see exactly what they expect and if they do expect you to use their forms.

Then research the links Marc provided.

From a practical perspective - If you have a complex part be prepared to put a lot of time into the process. I would work the labor and materials involved in this into the piece price, or as a one time charge. It's not something I would do for free unless there is a guarantee of a lot of sales negotiated.

You'll likely need to do Process Maps, Process Controls (possibly with FMEA), bubbled prints, FAI on just about every dimension and note on the prints, Capability Analysis on CTQs, full material certs... and then some
 

harley123

Starting to get Involved
#5
Thanks Scottk.

I will get with our customer. The information you gave me is what I am afraid of.
We do complete axle assemblies. Some have 40 or 50 components. It could take
along time to go through all of them.
 
#6
For a large assy, with any luck they'll send you a level IV with only a few items specified - Part Submission Warrant, Control Plan, etc. Also be prepared to try to negotiate with over zealous demands. More than once I've asked if we really needed to run capability charts for 100 sets of wires 6 feet long with a 6" tolerance only to find the buyer just sent the form over with no real knowledge of the assy. (not the way it's supposed to work...)
 

Miner

Forum Moderator
Staff member
Super Moderator
#7
For a large assy, with any luck they'll send you a level IV with only a few items specified - Part Submission Warrant, Control Plan, etc. Also be prepared to try to negotiate with over zealous demands. More than once I've asked if we really needed to run capability charts for 100 sets of wires 6 feet long with a 6" tolerance only to find the buyer just sent the form over with no real knowledge of the assy. (not the way it's supposed to work...)
Just remember, you have to do 100% of the PPAP regardless of level. The level only refers to how much must be sent to the customer. All of it must be retained on file.
 
#8
True. In my case however, we build wiring harnesess in a very high-mix low volume business. If your company builds electric mousetraps and you want 100 wire leads for a one time order and request a PPAP because your engineer used to be in Automotive, that's a hard "No." It happens.
 
#10
Just remember, you have to do 100% of the PPAP regardless of level. The level only refers to how much must be sent to the customer. All of it must be retained on file.
Hello Miner,

what about level 4? Isn't it like you define what has to be submitted/retained and not defined requirements can be "skipped"?
For example, I received from the customer below requirements:
"PPAP Leve IV: Please submit below documents:
1. Design Record
7. Control Plan
9. Dimensional Results
14. Samples (5 pcs)
18. PSW"

My understanding was, that I need to submit above documents and nothing to retain...

Thank you in advance for reply
 

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