PPAP 101

What is PPAP?

PPAP is a procedure companies use to ensure that the quality of parts manufactured by suppliers is up to standard. PPAP is an acronym for Product Part Approval Process. It ensures the manufacture and supply of parts are consistent. PPAP originates from the automotive and aerospace manufacturing industry.

PPAP involves an 18-step process to ensure that the parts produced meet the required quality at all times. Although PPAP started in the aerospace and automotive industry, many manufacturing companies use the process in their production routine. PPAP occurs in the fourth phase of APQP.

The Product Part Approval Process has a clear set of guidelines. This makes it easier for product manufacturers to know what clients or customers expect from them. The PPAP is especially helpful in ensuring that every product delivered is up to par. The process reduces the chances of things going wrong. The 18 steps in the PPAP include:

The 18 Elements of PPAP

1. Design Documentation

This step involves the drawings and designs of the product. It also ensures that everything about the product order aligns properly.

2. Engineering Change Notice

This step only occurs if there is a change or improvement to be made to an existing part or product.

3. Customer Approval

During the PPAP process, evidence of approval from the client’s engineering department is needed for the product or part.

4. DFMEA

DFMEA means Design Failure Mode and Effects Analysis. During this stage, the risks involved and the probability of product failure will be assessed.

5. Process Flow Diagram

This diagram displays all the steps taken to produce the part or product. The entire manufacturing process is listed on it.

6. PFMEA

Process Failure Mode and Effects Analysis evaluates the possibilities of failure in the process of manufacturing the product.

7. Control Plan

Based on the possibilities discovered in PFMEA, preventive measures will be implemented to counter problems if necessary. These measures are the control plan.

8. Measurement System Analysis

The information about the necessary equipment that will be used and their specification will be recorded in this stage.

9. Dimension Layout Results

In this phase, the measurements on the product or part design will be checked to see if they are correct.

10.  Design Verification and Plan Report

The design verification and plan report is a record that shows details of the test performed on the product. It also notes all the important certifications for the materials.

11. Statistical Process Control

This element of PPAP involves documenting the manufacturing process and the parts that make up the product.

12. Qualified Laboratory Documentation

The certifications of any laboratory testing that took place in the manufacturing process will be recorded here.

13. ARI

ARI stands for Appearance Removal Inspection. It ensures that the client or customer has accepted the product’s appearance.

14. Sample Production Parts

In this stage, a product sample will be delivered to the customer, so it can be approved.

15. Master Sample

The master sample is a prototype of the final product. It also requires the approval of the customer.

16. Checking Aids

A checking aid lists all the things that need to be checked during the production process.

17. Customer Specific Requirements

If the customer has any special requirements, they will be noted here.

18. Part Submission Warrant Form

This element includes the summary of the PPAP and all signatories.

Conclusion

PPAP stands for Production Part Approval Process. It involves an 18-step process that ensures that the quality of parts delivered is of high quality all the time. The process ensures that everything is carefully considered when manufacturing products to ensure maximum quality and minimal risk.