Production Part Approval Process

PPAP
Fourth Edition
 FOREWORD TO THE FOURTH EDITION
Effective June 1, 2006, PPAP Fourth Edition replaces PPAP Third Edition, unless otherwise specified by
your customer.
Production Part Approval Process (PPAP) is updated to the 4th edition to incorporate the customer
focused process approach associated with ISO/TS 16949:2002 and other changes listed below to update
requirements.
PPAP’s purpose continues to be to provide the evidence that all customer engineering design record and
specification requirements are properly understood by the organization and that the manufacturing
process has the potential to produce product consistently meeting these requirements during an actual
production run at the quoted production rate.
PPAP 4th Edition includes the following changes:
• Alignment of PPAP to the ISO/TS 16949:2002 process approach, including:
Š Aligning the order of the PPAP requirements with the automotive product development and
manufacturing process
Š Inclusion of an example process flow for PPAP
• Relocation of Customer Specific Instructions to appropriate websites, (e.g. OEM and IAOB,
www.iaob.org) to provide current requirements
• Update of Truck OEM requirements and moved to Appendix H
• Revised PSW (Part Submission Warrant) to:
Š Provide a more logical flow for the part / design description fields
Š Make the supplier address fields applicable to international locations
Š Include IMDS materials reporting to indicate reporting status
• Updated specific PPAP requirements, including:
Š Materials reporting and polymeric identification requirements in the design record
Š Process capability index usage (Cpk and Ppk)
Š The definition and approval of catalog parts and the definition of black box parts
• Modified customer notification and submission requirements to align with OEM requirements
(e.g., I.3.3 from PPAP 3rd removed)
• Clarified and commonized Appendices C, D, and E to match the PPAP reporting requirements
• Revised Tire Appendix to allow OEM specification of applicability and to eliminate duplications
with allowances already provided in the PPAP requirements
Note: The Tire Appendix is not applicable to organizations supplying tires to Ford Motor Company.
• Reorganized and updated Appendix F to stress the importance of the Bulk Materials Checklist
Note: Ford Motor Company requires all organizations supplying bulk material to Ford Motor Company to
comply with PPAP.
• Revised Glossary to be consistent with the updates in the text
PPAP refers to the following reference manuals: Advanced Product Quality Planning & Control Plan,
Potential Failure Modes and Effects Analysis, Measurement System Analysis, and Statistical
Process Control. These manuals are authored by DaimlerChrysler Corporation, Ford Motor Company,
and General Motors Corporation and are available through the Automotive Industry Action Group (AIAG)
at www.aiag.org.
The Supplier Quality Requirements Task Force gratefully acknowledges the contributions of the many
individuals and their respective companies that participated in the revision process.

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TABLE OF CONTENTS

INTRODUCTION.....................................................................................................................................................1
Purpose .................................................................................................................................................................1
Applicability..........................................................................................................................................................1
Approach ..............................................................................................................................................................1

SECTION 1 – GENERAL .........................................................................................................................................3

1.1 Submission of PPAP ................................................................................................................................3

SECTION 2 – PPAP PROCESS REQUIREMENTS.................................................................................................3

2.1 Significant Production Run......................................................................................................................3

2.2 PPAP Requirements.................................................................................................................................3

2.2.1 Design Record ......................................................................................................................................................... 4
2.2.2 Authorized Engineering Change documents ........................................................................................................... 5
2.2.3 Customer Engineering Approval ............................................................................................................................. 5
2.2.4 Design Failure Mode and Effects Analysis (Design FMEA)................................................................................... 5
2.2.5 Process Flow Diagram(s) ........................................................................................................................................ 5
2.2.6 Process Failure Mode and Effects Analysis (Process FMEA) ................................................................................. 5
2.2.7 Control Plan............................................................................................................................................................. 5
2.2.8 Measurement System Analysis Studies ................................................................................................................... 6
2.2.9 Dimensional Results................................................................................................................................................ 6
2.2.10 Records of Material / Performance Test Results ................................................................................................... 6
2.2.11 Initial Process Studies............................................................................................................................................ 7
2.2.12 Qualified Laboratory Documentation.................................................................................................................. 10
2.2.13 Appearance Approval Report (AAR) .................................................................................................................. 10
2.2.14 Sample Production Parts...................................................................................................................................... 10
2.2.15 Master Sample..................................................................................................................................................... 10
2.2.16 Checking Aids ..................................................................................................................................................... 11
2.2.17 Customer-Specific Requirements ........................................................................................................................ 11
2.2.18 Part Submission Warrant (PSW) ......................................................................................................................... 11

SECTION 3 – CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS .....................................13

3.1 Customer Notification.................................................................................................................................13

3.2 Submission to Customer..............................................................................................................................15

SECTION 4 – SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE.........................................................17

4.1 Submission Levels .......................................................................................................................................17

SECTION 5 – PART SUBMISSION STATUS.......................................................................................................19

5.1 General .......................................................................................................................................................19

5.2 Customer PPAP Status ...............................................................................................................................19

5.2.1 Approved ........................................................................................................................................................... 19
5.2.2 Interim Approval ............................................................................................................................................... 19

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 5.2.3 Rejected ............................................................................................................................................................. 19

SECTION 6 – RECORD RETENTION ..................................................................................................................21

APPENDICIES
APPENDIX A – COMPLETION OF THE PART SUBMISSION WARRANT (PSW) .............................................................22
APPENDIX B – COMPLETION OF THE APPEARANCE APPROVAL REPORT ...................................................................26
APPENDIX C – PRODUCTION PART APPROVAL, DIMENSIONAL RESULTS..................................................................29
APPENDIX D – PRODUCTION PART APPROVAL, MATERIAL TEST RESULTS ..............................................................31
APPENDIX E – PRODUCTION PART APPROVAL, PERFORMANCE TEST RESULTS ........................................................33
APPENDIX F – BULK MATERIAL - SPECIFIC REQUIREMENTS ....................................................................................35
APPENDIX G – TIRES - SPECIFIC REQUIREMENTS .....................................................................................................55
APPENDIX H – TRUCK INDUSTRY - SPECIFIC REQUIREMENTS ..................................................................................57

GLOSSARY............................................................................................................................................................65

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INTRODUCTION
Purpose
Production Part Approval Process (PPAP) defines generic requirements for production part approval,
including production and bulk materials (see Glossary). The purpose of PPAP is to determine if all
customer engineering design record and specification requirements are properly understood by the
organization and that the manufacturing process has the potential to produce product consistently meeting
these requirements during an actual production run at the quoted production rate.

Applicability
PPAP shall apply to internal and external organization sites (see Glossary) supplying production parts,
service parts, production materials, or bulk materials. For bulk materials, PPAP is not required unless
specified by the authorized customer representative.
An organization supplying standard catalog production or service parts shall comply with PPAP unless
formally waived by the authorized customer representative.
NOTE 1: See customer-specific requirements for additional information. All questions about PPAP
should be addressed to the authorized customer representative.
NOTE 2: A customer can formally waive PPAP requirements for an organization. Such waivers can only
be issued by an authorized customer representative.
NOTE 3: An organization or supplier requesting a waiver of a PPAP requirement should contact the
authorized customer representative. The organization or supplier should obtain documentation of waivers
from the authorized customer representative.
NOTE 4: Catalog parts (e.g., bolts) are identified and/or ordered by functional specifications or by
recognized industry standards.

Approach
The word “shall” indicates mandatory requirements. The word “should” indicates a recommendation.
Paragraphs marked “NOTE” are for guidance in understanding or clarifying the associated requirement.
The word “should” appearing in a NOTE is for guidance only.
For the purposes of PPAP, the terms and definitions given in ISO/TS 16949 and the PPAP Glossary
apply.