Introduction to APQP and its phases.

PPAP (Production Part Approval Process) is very common term used within automotive part manufacturers or OEM’s. Basically it is one of the core tools of quality and it indicates the confirmation of the Customer Specific Requirements which is one of the goals of TS16949 / IATF 16949. Before moving to the methodology of PPAP, let’s discuss the TS16949 / IATF16949 goals and its relation with the core tools of quality.

Goals of TS 16949 / IATF 16949:2016 implementation
1. Continual Improvement for Quality Management System.
2. Defect Prevention.
3. Variation Reduction.
4. Waste Reduction.
5. Customer Specific Requirements.
IATF 16949 has only 4 goals as the 5th Customer Specific Requirement is included in the clauses.

Core tools of quality
1. APQP (Advanced Product Quality Planning)
2. PPAP (Production Part Approval Process)
3. FMEA (Failure Mode Effect Analysis)
4. SPC (Statistical Process Approach)
5. MSA (Measurement System Analysis)

Relation of Core tools with TS / IATF goals
1. Continual Improvement for Quality Management System – APQP
2. Defect Prevention – FMEA
3. Variation Reduction – SPC & MSA
4. Waste Reduction – SPC & MSA
5. Customer Specific Requirements – PPAP
Now, let’s discuss about PPAP (Production Part Approval Process).

History of PPAP
Initially was developed by AIAG in 1993 with inputs from 3 automotive giants Ford, Chrysler & General Motors.

Importance of PPAP
As discussed earlier submission of PPAP indicates that the supplier has understood all the customer specific requirements.
PPAP indicates the capability of an organization to meet customer requirements.

Submission of PPAP
PPAP is submitted during,
New Part Development.
Change in tooling / Process / Machine / location / sub- supplier etc.
The current version of PPAP is 4th edition and the controlling authority is AIAG. (Automotive Industry Action Group)
PPAP is required to be submitted for more than 300 consecutive parts or manufacturing process run from 1 to 8 hrs.
Generally there are 19 elements of PPAP and 5 levels of submission as follows,

	PPAP Submission/Retention Requirements Table
		Requirements	Submission Levels
			1	2	3	4	5
	1	Design Record (if applicable)   (Drawings)	R	S	S	*	R
	2	Engineering Change Documents, if any	R	S	S	*	R
	3	Customer Engineering approval, if required	R	R	S	*	R
	4	Design FMEA (If applicable) (In case of proprietary organizations)	R	R	S	*	R
	5	Process Flow Diagrams  (Covering all processes from receiving to dispatch)	R	S	S	*	R
	6	Process FMEA   (Failure Mode Effect Analysis)	R	S	S	*	R
	7	Control Plan      (Robust controls defined for all the processes)	R	S	S	*	R
	8	Measurement System Analysis Studies    (GRnR and ndc study of gauges used for measuring critical dimensions)	R	R	S	*	R
	9	Layout Report and dimensional report  (Covering all dimensions and notes with ballooned drawings)	R	S	S	*	R
	10	Material, Performance Test Results  (Covering tests as per standards or drawings)	R	S	S	*	R
	11	Initial Process Studies      (SPC study for critical parameters)	R	R	S	*	R
	12	Qualified Laboratory Documentation (NABL qualified lab documents for calibration and material testing)	R	S	S	*	R
	13	Appearance Approval Report (AAR), if applicable	S	S	S	*	R
	14	Sample Product if applicable	R	S	S	*	R
	15	Master Sample( To be retained at supplier end with Validity period)	R	R	R	*	R
	16	List of checking aids with calibration frequency (as mentioned in control plan)	R	R	S	*	R
	17	Records of Compliance With Customer-Specific Requirements	R	R	S	*	R
	18	Part Submission Warrant (PSW)	S	S	S	S	R
	19	Bulk Material Checklist (in case of Bulk material PPAP)	S	S	S	S	R
S: The Organization shall submit to customer and retain a copy of records/documentation at organization's manufacturing location.
R: The organization shall retain at the manufacturing locations and make it available upon request by customer.
*: The organization shall submit or retain as per guidelines given by customer.

Submission levels are decided by the customer but “Level 3” is considered as the default level of submission as per AIAG.
These are generic requirements for PPAP submission.