Let's discover the PPAP Documentation

As part of my assignments as an external quality consultant, I am sometimes responsible for managing a PPAP (Production Part Approval Process) file.

The PPAP is a set of documents primarily used in the automotive industry to ensure that supplied parts meet customer specifications and requirements before the start of mass production.

There are five submission levels in the PPAP, each with different documentation requirements. Here is an explanation of the different levels:

1. Level 1: Submission of the Part Submission Warrant (PSW) only

• This is a declaration confirming that the produced part complies with the customer’s specifications and requirements.

2. Level 2: PSW with part samples and limited supporting documentation

• The supplier must provide a few part samples along with limited documentation (such as the control plan or FMEA – Failure Mode and Effects Analysis).

3. Level 3: PSW with part samples and complete supporting documentation

• The supplier must submit part samples along with all required PPAP documents (drawings, specifications, test reports, measurement results, etc.).

4. Level 4: PSW with other customer-specific requirements

• The customer defines the specific documents and samples they want to review. They may request some or all of the PPAP elements depending on their needs.

• This level is used for complex parts or situations where the customer requires tighter control over the validation process.

5. Level 5: PSW with part samples and on-site review of PPAP documentation

Typical Contents of a PPAP FileA PPAP file includes several mandatory documents, such as:

• PSW (Part Submission Warrant): The main document confirming part compliance.

• Control Plan: Describes the quality control methods used to ensure parts meet the requirements.

• FMEA (Failure Mode and Effects Analysis): Risk analysis related to the part’s manufacturing process.

• Process Capability Report: Assessment of the process’s ability to produce compliant parts.

• Part Samples: Physical representations of the parts for validation.

• Test Results: Evidence that the part meets technical, functional, and regulatory specifications.

Each PPAP level is selected based on the complexity of the part, its importance to safety, and customer requirements.