PPAP: Production Part Approval Process.

The Production Part Approval Process (PPAP) is published by the Automotive Industry Action Group (AIAG) as the AIAG PPAP manual, with the Fourth Edition (2006) the current reference. PPAP is the formal mechanism by which an automotive component supplier obtains customer approval for production parts. The supplier submits a defined documentation package demonstrating that engineering design and specification requirements are properly understood and that the production process has the capability to produce parts meeting those requirements consistently during an actual production run at the quoted production rate.

Five submission levels are defined. Level 1 requires only the Part Submission Warrant (PSW). Level 2 requires PSW with product samples and limited supporting data. Level 3 is the default and requires PSW with product samples and complete supporting data. Level 4 is customer-defined. Level 5 requires PSW with product samples and complete supporting data reviewed at the supplier's manufacturing site rather than submitted to the customer. The customer specifies the level for each part.

The 18 PPAP elements include the design record, authorised engineering change documents, customer engineering approval, design FMEA, process flow diagram, process FMEA, control plan, measurement system analysis (MSA) studies, dimensional results, material and performance test results, initial process studies, qualified laboratory documentation, appearance approval report (AAR), sample production parts, master sample, checking aids, customer-specific requirements, and the Part Submission Warrant. Detroit Three OEMs (Ford, General Motors, and Stellantis North America) and most global OEMs operating in the US require PPAP submission. The European VDA 2 PPF process serves a comparable function but is not directly substitutable for AIAG PPAP at US OEM plants.