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Open the free PPAP Checklist & PSW tool and click Load sample: it reproduces the case study below.
What PPAP is for
The production part approval process proves to the customer that the supplier understands all design and specification requirements and that the production process can make conforming parts consistently, at the quoted rate, with series tools, gauges, operators and material. It is defined in the AIAG PPAP manual (4th edition) and required by IATF 16949 clause 8.3.4.4 for product and manufacturing process approval.
Submission levels
| Level | What goes to the customer |
|---|---|
| 1 | PSW only (and appearance approval report if applicable) |
| 2 | PSW with product samples and limited supporting data |
| 3 | PSW with product samples and complete supporting data (default) |
| 4 | PSW and other requirements as defined by the customer |
| 5 | PSW with samples and complete data reviewed at the supplier site |
Key point
Step by step
- Clarify the scope: part number, drawing revision, submission level, reason for submission and customer-specific requirements (portal, forms, IMDS, packaging approval).
- Plan the elements in the PPAP checklist with owner and due date; link them to the APQP plan.
- Freeze the documents: DFMEA (if design responsible), process flow, PFMEA and control plan must describe the same process.
- Run the significant production run: series conditions, usually 1 to 8 hours and at least 300 consecutive parts unless the customer specifies otherwise. Verify the rate with a run at rate.
- Measure: full dimensional results on the agreed number of parts, material and performance tests, initial process studies (Ppk ≥ 1.67 is the usual acceptance criterion) and MSA for the control plan gauges.
- Sign the PSW only when every result meets the requirements; otherwise explain the deviation in the comments and ask for interim approval.
Example: tooling transfer of a die-cast housing
A supplier moves a die-casting tool for housing 4711-200-01 to a second plant. The customer asks for a level 3 submission. The team updates the process flow, PFMEA and control plan for the new cell, measures five parts per cavity, repeats the leak test and runs a capability study on the critical bore. The bore reaches Ppk 1.52 against a requirement of 1.67, so the PSW is submitted with a comment and an action plan, and the customer grants interim approval for three months.
Common mistakes
- PFMEA, control plan and work instructions describe different processes.
- Capability studies from a pilot tool instead of the series tool.
- MSA missing for gauges listed in the control plan.
- Dimensional results without the drawing revision or with ballooning that does not match the drawing.
- PSW signed although a result does not meet the requirement.
For German OEMs compare with the VDA production process and product approval.
Frequently asked questions
Which PPAP level is the default?
Level 3 (PSW with product samples and complete supporting data) is the default in the AIAG PPAP manual unless the customer specifies another level.
What is the difference between submit and retain?
Submitted elements go to the customer with the PSW. Retained elements stay at the supplier but must be available to the customer on request, so they have to be complete as well.
When is a new PPAP needed?
For a new part, an engineering change, tooling transfer or refurbishment, a new sub-supplier or material source, a change of manufacturing location, tooling inactive for more than a year and similar triggers listed in the manual, unless the customer waives the submission.
Is PPAP the same as VDA PPF?
No. Both approve production parts, but German OEMs usually require the VDA 2 production process and product approval (PPF) with its own forms and submission levels. Check the customer-specific requirements.