Production Part Approval Process (PPAP) is a standardized method used in the automotive industry to ensure that the components and materials used in a vehicle meet the required specifications before being put into production. PPAP is a detailed process that involves a thorough evaluation of the supplier’s processes and controls to ensure that the product meets the customer’s requirements. The process includes documentation, inspection, testing, and validation of the parts, and also requires a formal submission of the results to the customer for review and approval. PPAP provides a structured approach to identify and address potential issues early in the production process, thus reducing the risk of defects, delays, and recalls. PPAP helps ensure that suppliers and manufacturers are working together to produce high-quality products that meet customer requirements and specifications.
The Production Part Approval Process (PPAP) is a standardized method used in the manufacturing industry, particularly in the automotive sector, to ensure that the components and materials used in the production process meet the required specifications before they are put into use. PPAP is a detailed process that includes various steps, including documentation, inspection, testing, and validation of the parts.
The main purpose of the PPAP process is to provide a structured approach for identifying and addressing potential issues early in the production process, thereby reducing the risk of defects, delays, and recalls. The process involves a thorough evaluation of the supplier’s processes and controls to ensure that the product meets the customer’s requirements. It also requires a formal submission of the results to the customer for review and approval.
PPAP is an important quality assurance tool that helps ensure that suppliers and manufacturers are working together to produce high-quality products that meet customer requirements and specifications. By following the PPAP process, manufacturers can ensure that their products are safe, reliable, and meet or exceed the expectations of their customers. Overall, PPAP is an essential part of the quality management system in the manufacturing industry.
The Production Part Approval Process (PPAP) was first developed in the late 1980s by the Automotive Industry Action Group (AIAG) in response to the growing need for a standardized approach to quality management in the automotive industry. The AIAG recognized the importance of ensuring that the components and materials used in the production process met the required specifications, and that any potential issues were identified and addressed early in the process.
Initially, PPAP was developed specifically for the automotive industry, but it has since been adopted by other industries, such as aerospace and medical devices. The PPAP process has undergone several revisions over the years, with the latest version being released in 2018.
The adoption of PPAP has helped to improve the quality of products in the automotive industry by ensuring that all components and materials meet the required specifications and that any potential issues are identified and addressed before they become major problems. PPAP has become an essential part of the quality management system for many manufacturers, and it continues to evolve to meet the changing needs of the industry.
Hi, Welcome to all of you On your blog site. Today we will know about What is PPAP? Its 18 elements as per AIAG manual In this session we will cover brief description about the requirement of PPAP Production Part Approval Process, list of document in as per AIAG PPAP manual so that a basic platform can be set to access next step. So requesting to you if you want to learn about this so please read this article carefully from beginning to end and I am confident that your attention during reading surely enhance your skill about What is PPAP? Its 18 elements as per AIAG and as we know we all carried out these things in routine basis. It means your knowledge will enhance and your competency will upgrade .
We are going to focus on keep up in this article we are going to cover below mention content one by one.
In this article mainly we are going to focus on What is PPAP? Its 18 elements as per AIAG.
Content table
- Introduction about PPAP
- Defination of what is Production Part Approval Process (PPAP)
- Requirement of PPAP
- Brief Introduction about What is PPAP? Its 18 elements as per AIAG
- When to do PPAP
- Method for carried out PPAP (Production Part Approval Process)
- Level of PPAP
- Elements of PPAP
- Quick Summary
All content item will be covered in this topic and help you to get clear understanding about PPAP document its requirements and different levels of PPAP. Finally you will get understanding about What is PPAP? Its 18 elements as per AIAG so keep focusing on content.
So without wasting the time let’s enjoy the topic
Introduction about PPAP
Production Part Approval Process (PPAP) is one of AIAG core tool which his required to build the confidence of customer in supplier and their production process. It specify the requirement and process which his required to follow by supplier which le he is producing a new part or any other condition which his specified in AIAG manual. Conducting PPAP is also a key requirement of IATF standard for automotive industry. As per IATF an organization need to follow the defined PAPP process and ensure its implementation and Maintain it during production approval of product by customer same has to be followed by the its supplier to avoid any issue in supply chain. After carried out it organization need to retail the record as per customer specific requirement in respect of PPAP.
Defination of what is Production Part Approval Process (PPAP)
PPAP is defined as the approval process for new product or any revision product which is being produced from same process or any new or revised production method .PPAP is a set of document .in this set there are 18 document which hare very important to get approval of nay production process in automotive industry. these all 18 document some of need to submitted to customer or some not need .based on the level of approval .In PPAP there are Five level of approval and documents are being shared as per defined level.it will help to understand about What is PPAP? Its 18 elements as per AIAG.
Requirement of PPAP
It is a key requirement of IATF to carry out PPAP to verify that the supplier understand the customer requirement and he is being able to meet the customer requirement with consistency of producing the product and meet the customer requirement at specified rate without any failure.
Talk about PPAP it is one of the core tools of AIAG.
AIAG stands for automotive industries action group. They are five core tools as per AIAG.
When to do PPAP
As per requirement of IATF Process of PPAP is need to carried out by supplier in case of supplying new part to customer or and revision of existing part ,on any change in current production process etc. there are some key items are mentioned in PPAP manual in respect of requirement in which case PPAP is required to submit
Method for carried out PPAP (Production Part Approval Process)
As we know it’s a process so to perform PPAP there are set of requirement which his need to carried out by suppler prior to ship the produced part to customer .A well standard production line is create and the product ion is run on that line in presence of customer for 8 hours shift or 300 no’s of production parts or any customer specific requirement in respect of PPAP carried out.
Level of PPAP
PPAP is stands for production part approval process so it is activities which is carried out whenever we are going to approve any process that is producing some product.
The process of approving any organisation process is defined on the stages of production because as we know
There are five level of PPAP as per AIAG manual of PPAP. Which are mentioned below:
Level 1 – Submission of only Part Submission Warrant (PSW) to the customer.
First level of PPAP describe by AIAG. In this set of limited documents required to submit to customer at the time of PPAP approval. PSW is mandatory to submit in this level.
Level 2 – Submission of PSW with product samples and limited supporting data as per matrix.
It is second level of people as like level 1 is set of identified document need to submit to customer at the time of PPAP approval. This level of submission is depend on the customer. When customer ask level two people we have to submit they will do people.
Level 3 – Submission of PSW with product samples and complete supporting data (generic level).
Another level of PPAP submission. This is generic level of PPAP. In this level all 18 documents have to submit to customer for approval of PPAP. Customer requirement to share other document that these 18 document that organisation have to share all the document as per customer requirement.
Level 4 – Submission of PSW and other requirements as defined by the customer. This is level 4 people submission in this level customer demands psw and some key documents which are required to approve running production process.
Level 5 –Submission of PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location.
Elements of PPAP:
As we discuss that PPAP is s set of document which hare need to carry out while performing or carried out PPAP process. These documents are the key requirement of PAP which his build the customer confidence that the supplier can meet his requirement without any failure .below are the list of these 18 PPAP documents:
- Design Documentation
2. Engineering Change Documentation
3. Customer Engineering Approval
4. Design Failure Mode and Effects Analysis
5. Process Flow Diagram
6. Process Failure Mode and Effects Analysis
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
10. Records of Material / Performance Tests
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer Specific Requirements
18. Part Submission Warrant .
These 18 elements are part of a PPAP package which are identified by AIAG to comply the requirement of PPAP. These all 18 elements are not only element but these are 18 documents.
These 18 documents are linked with each other in a sequential way to perform a process effectively from input to output.
Discuss about these are 18 elements of PPAP which are decided by the AIAG manual.
This 18 elements are not mandatory to submit at the time of PPAP submission but these all 18 elements are submitted according to level of PPAP.
PPAP having five levels of submission in which documents are identified out of these 18 elements which are required to submit according to level.
The person who is preparing and submit PPAP must have complete knowledge about PPAP requirements as per AIAG PPAP manual.
PPAP is not a invention it is requirements of top OEM customer which having multiple set of documents in it.
So it’s very important to choose documents as defined level.
The best level of PPAP submission is used word wide is level 3 in which all these 18 documents are submitted to customer.
When when you will be read AIAG PPAP manual you will find that in some levels of PPAP it is only 4 to 5 documents are required to submit.
Which is mandatory to submit for PPAP app approval is PSW( part submission warrant).
For details of PFD AIAG PPAP manual can refer and use the specific layout use for PFD design.
Yes we have to consider the rejected part in PPAP as COPQ because COPQ is related to cost that waste on rejection which can be any type.
Quick Summary
In brief if you talk about the article on What is PPAP? Its 18 elements as per AIAG . During this whole topic we focused on PPAP it’s requirement. PPAP is a systematic process which his defined to maintain a common platform at supplier end so that he can meet the customer requirement without any failure and it build the confidence of customer in respect of supplier .This complete process describe that the supplier understand the requirement of customer in respect of product and he is capable to meet the requirement without any failure, this process is carried out to avoid major failure in supply chain of process. This complete process is approved by customer hence only after approval of PPAP a supplier can ship product to customer end.
The Production Part Approval Process (PPAP) is a significant tool for businesses in the manufacturing industry, especially in sectors such as automotive, aerospace, and medical devices. Implementing the PPAP process can bring several benefits to a business, including:
- Quality Assurance: PPAP ensures that the components and materials used in the production process meet the required specifications, reducing the risk of defects and recalls.
- Cost Reduction: By identifying and addressing potential issues early in the production process, PPAP can help reduce the cost of rework, scrap, and warranty claims.
- Customer Satisfaction: PPAP helps ensure that products meet or exceed customer expectations, improving customer satisfaction and loyalty.
- Regulatory Compliance: In many industries, such as automotive and aerospace, PPAP is a requirement for regulatory compliance.
- Improved Supplier Relationships: By working collaboratively with suppliers to ensure that their products meet customer requirements, PPAP can help strengthen supplier relationships and improve supply chain performance.
Overall, the PPAP process is an essential part of the quality management system for businesses in the manufacturing industry. It can help businesses produce high-quality products, reduce costs, and improve customer satisfaction and relationships with suppliers.
The Production Part Approval Process (PPAP) has several advantages and disadvantages. Here are some of the pros and cons:
Pros:
- Quality assurance: PPAP ensures that all components and materials used in the production process meet the required specifications, reducing the risk of defects and recalls.
- Risk mitigation: By identifying and addressing potential issues early in the production process, PPAP can help reduce the risk of delays and costly rework.
- Regulatory compliance: PPAP is often required in many industries to comply with regulations and standards.
- Improved customer satisfaction: PPAP helps ensure that products meet or exceed customer expectations, improving customer satisfaction and loyalty.
- Improved supplier relationships: By working collaboratively with suppliers to ensure that their products meet customer requirements, PPAP can help strengthen supplier relationships and improve supply chain performance.
Cons:
- Time-consuming: The PPAP process can be time-consuming and require a significant amount of resources.
- Costly: Implementing PPAP can be expensive, especially for small businesses.
- Inflexible: The PPAP process is a standardized approach, which may not be suitable for all businesses and products.
- Complex: The PPAP process involves several steps and can be complex to implement and manage.
- Limited scope: PPAP only addresses the quality of components and materials used in the production process and does not address other aspects of the manufacturing process, such as design or assembly.
Overall, while PPAP has several advantages in terms of quality assurance, risk mitigation, and customer satisfaction, it can also be time-consuming, costly, and inflexible. Businesses need to weigh the pros and cons of PPAP to determine whether it is a suitable quality management tool for their needs.
Here are some frequently asked questions (FAQs) related to the Production Part Approval Process (PPAP):
- What is the PPAP process? The PPAP process is a standardized method used in the manufacturing industry to ensure that components and materials used in the production process meet the required specifications before they are put into use.
- When is PPAP required? PPAP is often required in many industries, such as automotive and aerospace, to comply with regulations and standards.
- What are the steps in the PPAP process? The PPAP process involves several steps, including documentation, inspection, testing, and validation of the parts.
- What documents are required for PPAP submission? The documents required for PPAP submission may vary depending on the industry and customer requirements, but typically include a control plan, process flow diagram, and dimensional measurements.
- Who is responsible for PPAP submission? The supplier is responsible for PPAP submission, but the customer may provide guidance and requirements for the submission.
- How long does the PPAP process take? The duration of the PPAP process can vary depending on the complexity of the product and the number of parts being produced. It can take several weeks to several months to complete the process.
- What are the benefits of PPAP? PPAP helps ensure that products meet or exceed customer expectations, reduces the risk of defects and recalls, and improves supplier relationships and supply chain performance.
- What are the challenges of implementing PPAP? The challenges of implementing PPAP can include the cost and time involved, the complexity of the process, and the need for a standardized approach that may not be suitable for all businesses and products.
- Can PPAP be used in other industries besides automotive and aerospace? Yes, PPAP has been adopted by other industries, such as medical devices and consumer products, to ensure product quality and compliance with regulations and standards.
- Is PPAP a requirement for ISO 9001 certification? PPAP is not a requirement for ISO 9001 certification, but it can be used as a quality management tool to ensure compliance with ISO 9001 requirements.
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What is PPAP? Its 18 elements as per AIAG
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