A PPAP, or Production Part Approval Process, is the standardized package of documents and sample parts a supplier submits to prove it can consistently produce a part to the specification before mass production begins. The OEM or Tier 1 customer reviews the PPAP and grants approval, interim approval, or rejection. No approved PPAP usually means no shipping.
Why PPAP Matters
PPAP exists so the customer can trust that the parts arriving on the line match the parts that were approved. It reduces launch risk, prevents defects from reaching the plant, and creates a documented record if a concern arises later. A late or rejected PPAP can delay a program launch and damage the supplier scorecard.
The 18 PPAP Elements
- Design records
- Engineering change documents
- Customer engineering approval
- Design Failure Mode and Effects Analysis (DFMEA)
- Process flow diagram
- Process Failure Mode and Effects Analysis (PFMEA)
- Control plan
- Measurement System Analysis (MSA)
- Dimensional results
- Material and performance test results
- Initial process studies (capability)
- Qualified laboratory documentation
- Appearance Approval Report (AAR)
- Sample production parts
- Master sample
- Checking aids
- Customer-specific requirements
- Part Submission Warrant (PSW)
The 5 PPAP Submission Levels
The customer decides how much of the package the supplier must submit, from Level 1 to Level 5.
- Level 1: Part Submission Warrant only
- Level 2: PSW with product samples and limited data
- Level 3: PSW with product samples and full supporting data (the most common)
- Level 4: PSW and other requirements defined by the customer
- Level 5: PSW with samples and complete data reviewed at the supplier site
When Is a PPAP Required?
- A new part or product launching for the first time
- An engineering change to the part, material, or process
- A new or moved manufacturing location or tooling
- A change of sub-supplier for a component
- A customer request after a quality concern
Key takeaway: PPAP is how a supplier earns the right to ship. Getting it right the first time protects the launch and the scorecard. On-site support during launch keeps the PPAP and the plant aligned.
Frequently Asked Questions
What happens if a PPAP is rejected?
The supplier cannot ship approved production parts until the issues are corrected and the PPAP is resubmitted and approved. This can delay a launch and trigger customer scrutiny, so accuracy matters.
How does a quality liaison help with PPAP?
During launch, an on-site liaison coordinates between the plant and the supplier, confirms requirements, supports run-at-rate and sample builds, and helps resolve issues before they turn into a rejected submission or an escalation.