PPAP – Production Part Approval Process

The Production Part Approval Process (PPAP) is a detailed validation method designed to ensure that a manufacturer can consistently deliver components that meet client specifications, required volumes, and production rates. This quality assurance process consists of 18 defined requirements and was developed by the Automotive Industry Action Group (AIAG) to maintain high production standards. While originally implemented in the automotive and aerospace industries, PPAP is now a widely adopted standard across various sectors committed to delivering high-quality parts.

When Is PPAP Required?

PPAP approval is mandatory for every new production part and any modifications to existing parts or manufacturing processes. It is governed by the Advanced Product Quality Planning (APQP) system, which oversees product quality throughout development and mass production. Suppliers or manufacturing teams are responsible for preparing and submitting a PPAP package to the customer for approval.

Purpose of the PPAP Process

PPAP enables:

• Verification that a supplier can produce components at scale to client-defined quality standards.

• Confirmation that the supplier complies with production and quality norms.

• Understanding and documentation of customer-specific requirements.

• Alignment and transparency between supplier and client.

• Smooth market introduction of products.

• Reduced manufacturing costs and enhanced production reliability.

How the PPAP Process Works

The PPAP process begins with the submission of prototype parts to the customer for inspection and approval. Quality control spans planning, production, and post-production stages. Once the customer confirms PPAP documentation and the product meets all required specifications, serial production can commence.

Key Benefits of PPAP in Manufacturing

• Standardised process for approving production parts.

• Assurance of compliance with customer-specific requirements.

• Full traceability and control throughout the manufacturing process.

• Easier identification and resolution of quality issues.

• Shorter production times through early validation.

PPAP Submission Levels

There are five PPAP submission levels that define the required documentation based on customer needs:

Level 1 – Part Submission Warrant (PSW) Only

• No additional documentation required.

• May include an Appearance Approval Report (AAR) if requested.

Level 2 – PSW with Limited Supporting Data

• Includes product samples, material and performance test results, and AAR.

Level 3 – PSW with Complete Supporting Data

• Includes engineering approvals, Design FMEA, Process Flow Diagrams, Control Plans, Measurement System Analysis (MSA), and capability studies.

Level 4 – PSW with Customer-Specific Requirements

• All documents specified by the customer must be submitted.

Level 5 – PSW with Full Documentation Available for On-Site Review

• Includes all Level 3 and 4 data, and requires complete visibility of production processes at the supplier’s facility.

Each level uses the 18-element PPAP checklist. This documentation must be stored or provided upon request.

What Does a Complete PPAP Package Include?

A full PPAP documentation set consists of the following 18 elements:

1. Design Records (including customer and supplier drawings)

2. Documented Engineering Change Requests (if any)

3. Customer Engineering Approval

4. Design FMEA (Failure Mode and Effects Analysis)

5. Process Flow Diagram (PFD)

6. Process FMEA

7. Control Plan

8. Measurement System Analysis (MSA)

9. Dimensional Results

10. Material / Performance Test Results

11. Initial Process Studies (Process Capability)

12. Qualified Laboratory Documentation

13. Appearance Approval Report (AAR)

14. Sample Production Parts

15. Master Sample

16. Checking Aids

17. Compliance Certifications

18. Part Submission Warrant (PSW)

Customers review the documentation to ensure alignment with expectations and determine whether the part should be:

• Approved for full production,

• Conditionally approved with modifications,

• Rejected (requiring resubmission after corrections).

Rubber Components and O-Rings with PPAP

At Power Rubber, we offer high-quality rubber products and O-rings certified through the PPAP process. This ensures our clients receive consistent, high-performance parts that meet precise technical requirements. Whether for the automotive industry or other specialised sectors, our PPAP-compliant rubber components are designed to meet the highest quality standards.

For further information, contact us at +48 22 292 40 24 or +48 505 16 03 03, via email at Power@PowerRubber.com, or through our contact form.