What is PPAP?
Production
Part Approval Process. It is in conjunction with the APQP activities. Standard
used to reduce risks before product or service release.
Purpose?
Provide
evidence that the organization properly understands all customer engineering
design records and specification requirements. Demonstrate that the
manufacturing process has the potential to produce a product, that consistently
meets all requirements during an actual production run at the quoted production
rate.
Prevents use
of unapproved and non-conforming parts, Identifies issues early for resolution.
Reduces warranty charges and prevents the cost of poor quality. Assists with
managing supplier changes. Improves the overall quality of the product, and
increases Customer satisfaction.
When requires PPAP?
- New part production
- Modifications
- Construction or material change
- Production from new or modified tools and additional or replacement tooling needs PPAP submission.
- Change in part processing
- Tolling and equipment transferred to different plant sites or additional plant locations.
- Suppliers change
- Reuse an inactive tool for more than one year.
- Test/Inspection methods changes
- A new source of raw materials
- New color not previously supplied
- Correction of discrepancy on previously submitted parts needs PPAP submission.
- Design change
- New process technology
Steps
- Design documents (inc. All CAD data and specifications)
- Authorized Engineering change documents
- Customer Engineering Approval
- Design Failure Modes and Effects Analysis (DFMEA)
- Process Flow Diagram
- Process Failure Modes and Effects Analysis(PFMEA)
- Control Plan
- Measurement Systems Analysis
- Material Test Results
- Performance Test Results
- Initial Process Studies
- Qualified Laboratory Documentation
- Appearance Approval Report
- Sample Production Parts
- Master Sample
- Checking Aids
- Customers-Specific Requirements
- Part Submission Warrant(PSW)