Front page / What are PPAP levels 1 to 5, and what goes in a PPAP for a moulded part?
What are PPAP levels 1 to 5, and what goes in a PPAP for a moulded part?
PPAP, the Production Part Approval Process, is the automotive industry's method for showing that a supplier understands every design requirement and that the production process can meet them consistently at the quoted production rate. The submission level, from 1 to 5, decides how much evidence goes to the customer. Level 1 is the warrant form only. Level 3 sends the warrant, sample parts and complete supporting data. Level 5 keeps the complete data available for review at the supplier's site. The process has 18 possible elements, and the customer decides which apply.
The five submission levels
| Level | What the customer receives (Quality-One summary) |
|---|---|
| 1 | Part Submission Warrant (PSW) only |
| 2 | PSW with product samples and limited supporting data |
| 3 | PSW with product samples and complete supporting data |
| 4 | PSW and other requirements defined by the customer |
| 5 | PSW with product samples, with complete supporting data available for review at the supplier's manufacturing location |
Ask the customer which level applies before quoting, as levels 3 and 5 need much more work than level 1.
The 18 elements, grouped
| Stage | Elements | For a moulded part |
|---|---|---|
| Design | design records; engineering change documents; customer engineering approval; design FMEA | part drawing and model at the released revision; any changes agreed during mould trials |
| Process planning | process flow diagram; process FMEA; control plan | drying, moulding, trimming, inspection and packing steps, with risks and controls |
| Measurement | measurement system analysis (gauge R&R); checking aids | CMM programs, fixtures and go/no-go gauges, with calibration |
| Results | dimensional results; material and performance test records; initial process studies; qualified laboratory documentation | full layout, resin certificates, test reports, and capability studies on key dimensions |
| Appearance and samples | appearance approval report; sample production parts; master sample | colour, gloss and texture approval; signed master parts for comparison |
| Wrap-up | customer-specific requirements; Part Submission Warrant | the summary form, one per part number unless the customer says otherwise |
Quality-One notes that dimensional layout samples should be taken at random from a significant production run, usually at least 30 pieces, and that initial process studies use statistical process control charts on critical characteristics to show the process is stable and near nominal.
When a PPAP is needed
According to Quality-One, a PPAP is required for any new part and for any change to an existing part or process, and the customer can ask for one at any time. The PSW records the reason, such as a design change or annual revalidation. For moulding, moving a mould to another press or plant, building a replacement cavity, or changing resin grade are typical changes to raise with the customer.
Educational summary based on Quality-One and AIAG public pages. The AIAG PPAP manual and your customer's specific requirements govern actual submissions.
Questions buyers ask
Is PPAP only for automotive?
It began there and AIAG publishes the manual, but other industries borrow the approach, often at a simpler level.
Where does a multi-cavity mould fit?
Customers often require dimensional results for every cavity, because each cavity can differ. Confirm this when setting the submission level.
What is the master sample used for?
Quality-One describes it as a customer-signed final sample used to train operators and to compare against production parts if questions arise.
Is a PPAP the same as a first article inspection?
They overlap on dimensional checks, but PPAP adds process risk analysis, control plans, measurement studies and capability data.
Sources
- Quality-One International, Production Part Approval Process (PPAP)
- AIAG, PPAP manual, 4th edition