What are the 5 Levels of PPAP?

The Production Part Approval Process¹ (PPAP) is crucial in manufacturing, particularly in industries like automotive and rubber manufacturing. It ensures that suppliers meet the required specifications and quality standards before the production of parts begins.

The 5 levels of PPAP² help manufacturers assess product quality, with each level representing a different level of documentation and validation.

Let’s explore what PPAP is, its checklist, and the roles involved in the process.

What is Meant by Production Part Approval?

Production Part Approval is a process used by manufacturers to verify that a supplier can consistently produce parts that meet all specifications and quality requirements. It is a standard procedure in many industries, particularly in automotive manufacturing.

PPAP ensures that a supplier’s parts meet the required specifications before full-scale production begins.

The Purpose of PPAP

The goal of PPAP is to confirm that both the supplier and the manufacturer are aligned on product quality standards. This approval process reduces the risk of defects and ensures consistent production quality.

When is PPAP Needed?

PPAP is generally required when a new part is introduced, or when there is a change in design, materials, or production processes. It’s especially critical when suppliers are changing or when a part will be used in a mission-critical system like an HVAC system or automotive components.

PPAP vs. ISIR

While both Production Part Approval and Initial Sample Inspection Report (ISIR) ensure parts meet specifications, PPAP is more detailed and applies to mass production, while ISIR is typically used in the early stages of production for part validation.

What is a PPAP Checklist?

A PPAP checklist³ is a document that helps manufacturers and suppliers ensure all required elements are addressed during the approval process. It includes all the necessary documentation and testing results needed for production part approval.

The PPAP checklist ensures that manufacturers and suppliers submit all necessary documents for part approval, from design records to material certifications.

Key Elements of the PPAP Checklist

• Design Records: Documentation of the part design, including drawings and specifications.
• Engineering Change Documents: Any changes made to the design after the original approval.
• Material Certifications: Proof that the materials used meet the required standards.
• Process Flow Diagram: A detailed map of the manufacturing process.
• Control Plan: A plan to ensure that the part is consistently manufactured to specification.
• Measurement System Analysis: Verification that the measurement systems used for quality control are accurate.
• Production Trial Runs: Results from initial production runs to ensure parts meet specifications.

Who is Responsible for PPAP?

The responsibility for PPAP lies with both the supplier and the manufacturer. However, it is the supplier’s job to provide all the necessary documentation and perform testing to meet the required standards.

Both suppliers and manufacturers play key roles in PPAP. The supplier provides documentation and test results, while the manufacturer reviews and approves them.

Roles in PPAP

• Supplier: Responsible for submitting the required documents, providing test results, and ensuring part quality.
• Manufacturer: Reviews the submitted documents, tests the parts, and approves the production run if everything meets the required standards.
• Quality Assurance Team: Reviews test results and verifies compliance with the specifications.

What are the Steps in the PPAP Process?

The PPAP process consists of several steps designed to ensure the consistency and quality of production parts. Each step involves submitting specific documentation and performing tests to validate the parts.

The PPAP process consists of multiple steps to ensure parts meet specifications and quality standards before production begins.

Steps in the PPAP Process:

1. Part Submission: The supplier submits the parts along with all necessary documentation.
2. Part Approval: The manufacturer reviews the submission and approves or requests changes.
3. Production Trials: The supplier runs a trial production to validate the process and quality of the parts.
4. Test Reports: After the trial run, the supplier provides test reports to prove that the parts meet the required specifications.
5. Final Approval: Once all tests are passed and documents are reviewed, the manufacturer gives final approval to begin full-scale production.

PPAP Levels Overview

There are 5 levels of PPAP, each with varying requirements in terms of documentation and testing:

• Level 1: Basic submission with only the part itself.
• Level 2: Submission of the part along with a limited set of documents.
• Level 3: Full submission, including the part and a comprehensive set of documents.
• Level 4: A less common level where only specific documents are required.
• Level 5: The most comprehensive level, involving full submission, documents, and on-site review.

Conclusion

The PPAP process is a vital part of quality control, especially for manufacturers like those in the rubber and automotive industries. By following the 5 levels of PPAP and completing all necessary documentation and tests, suppliers can ensure that their parts meet the required specifications and quality standards before mass production begins. As manufacturers, we understand the importance of quality assurance, and PPAP plays a key role in maintaining that.

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