PPAP – 18 Elements Explained with Practical Examples

Production Part Approval Process (PPAP) is a structured method used in the automotive and manufacturing industries to ensure that suppliers understand customer requirements and that the manufacturing process consistently produces conforming products.

PPAP verifies that design records, engineering requirements, and production processes are properly documented and validated before mass production begins.

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Below are the 18 PPAP elements from the AIAG PPAP 4th Edition explained with simple examples.

1. Design Record

What it is

• Official engineering drawing or CAD model defining product specifications.

• Contains dimensions, tolerances, material specifications, and notes.

Example

• Automotive bracket drawing showing:

  • Hole diameter = 10 ±0.05 mm

  • Material = Mild Steel IS2062

  • Surface finish requirement.

2. Authorized Engineering Change Documents

What it is

• Documents that record design changes approved by the customer or engineering team.

Example

• Engineering Change Notice (ECN) changing:

  • Material from Aluminum to Stainless Steel

  • Hole diameter from 8 mm to 10 mm.

3. Customer Engineering Approval

What it is

• Approval from the customer confirming the design meets functional requirements.

Example

• OEM approval for a dashboard plastic component after testing fitment and durability.

4. Design FMEA (DFMEA)

(Applicable if supplier is responsible for product design)

What it is

• Risk analysis of potential failures in the product design.

Example

5. Process Flow Diagram

What it is

• Visual representation of the entire manufacturing process.

Example

Raw Material → Cutting → CNC Machining → Deburring → Inspection → Packing

6. Process FMEA (PFMEA)

What it is

• Risk analysis of failures during the manufacturing process.

Example

7. Control Plan

What it is

• Document defining how process and product quality will be controlled.

Example

8. Measurement System Analysis (MSA)

What it is

• Study verifying measurement equipment accuracy and repeatability.

Example

• Gauge R&R study for digital caliper measuring hole diameter.

Result Example
Gauge R&R = 8% (Acceptable)

9. Dimensional Results

What it is

• Actual measurement results compared with drawing specifications.

Example

10. Records of Material / Performance Test Results

What it is

• Evidence that the material and product meet specified requirements.

Example

• Tensile strength test report for steel component.

• Salt spray test report for corrosion resistance.

11. Initial Process Studies (Cp / Cpk)

What it is

• Statistical capability study proving process stability.

Example

Interpretation
Cpk > 1.67 → Process capable.

12. Qualified Laboratory Documentation

What it is

• Evidence that testing laboratories are accredited.

Example

• NABL / ISO 17025 certificate of laboratory performing material tests.

13. Appearance Approval Report (AAR)

(Applicable when appearance matters)

What it is

• Approval for visual characteristics such as color, texture, or finish.

Example

• Paint color approval for vehicle bumper.

14. Sample Production Parts

What it is

• Parts produced from actual production process and tooling.

Example

• 300 parts produced during trial run for PPAP submission.

15. Master Sample

What it is

• Approved reference sample kept for comparison.

Example

• One approved component stored at supplier site and one at customer site.

16. Checking Aids

What it is

• Fixtures, gauges, templates used for inspection.

Example

• Go/No-Go gauge for checking slot width.

17. Customer-Specific Requirements

What it is

• Additional requirements defined by OEM customers.

Example

• Ford requiring capability index Cpk ≥ 1.67

• Toyota requiring special packaging.

18. Part Submission Warrant (PSW)

What it is

• Final declaration confirming all PPAP requirements are completed.

Example

• Supplier signs PSW confirming:

  • All PPAP elements completed

  • Product meets customer requirements.

This document formally approves the part for mass production.

Level 1 – Part Submission Warrant Only

What is submitted

• Only the PSW (Part Submission Warrant).

When it is used

• For low-risk parts.

• For simple components.

• When customer already has confidence in the supplier process.

Example

• Standard fasteners supplied to an OEM with an already proven process.

Level 2 – PSW + Limited Supporting Data

What is submitted

• Part Submission Warrant (PSW)

• Limited supporting documents such as:

  • Dimensional results

  • Material test results

  • Process capability summary

When it is used

• Moderate risk components.

• When customer wants basic evidence but not the full PPAP package.

Example

• Sheet metal brackets supplied to a vehicle manufacturer.

Level 3 – PSW + Complete Supporting Data (Most Common)

What is submitted

• PSW

• Complete PPAP documentation package, including:

  • Design record

  • PFMEA

  • Process Flow Diagram

  • Control Plan

  • MSA studies

  • Capability studies

  • Dimensional results

  • Test results

  • Sample parts

When it is used

• Standard requirement for most automotive parts.

Example

• Automotive engine mounting bracket supplied to OEM.

Level 4 – PSW + Other Requirements Defined by Customer

What is submitted

• PSW

• Documents requested by customer

• Additional validation or testing as required.

When it is used

• High-risk components.

• Safety-critical parts.

Example

• Brake system component requiring additional validation and testing.

Level 5 – PSW + Complete Data Reviewed at Supplier Site

What is submitted

• PSW

• Full PPAP documentation.

Difference

• Instead of submitting documents, customer reviews them at the supplier manufacturing location.

When it is used

• Very critical components.

• New suppliers or complex manufacturing processes.

Example

• Transmission assembly components requiring on-site verification.

Typical PPAP Level Comparison

Key Points to Remember

• Level 3 is the default PPAP level used in most automotive projects.

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• The customer decides the required submission level.

• Higher levels require more detailed validation and documentation.

• All PPAP records must be retained even if not submitted to the customer.