PPAP Explained for Automotive Parts

PPAP means Production Part Approval Process. It is an AIAG-defined submission process used to demonstrate that engineering requirements are understood and that a production process can repeatedly make conforming parts at the quoted production rate.

In practice, PPAP is the evidence package a supplier assembles and submits so the customer can approve a part for production. It is not a single document. It is a set of records covering design, process, inspection and test evidence, closed out with a signed Part Submission Warrant (PSW).

PPAP sits inside a wider quality framework. IATF 16949:2016 clause 8.3.4.4 covers the product approval process, and OEM customer-specific requirements build on top of the AIAG manual.

PPAP is required when an automotive customer requires product approval before a part enters production. The customer defines the requirement, and the supplier produces the evidence.

• Automotive OEMs and their tier customers, who set the submission requirement for each part.
• Tier 1 and Tier 2 suppliers, who submit PPAP evidence to their customer.
• Sub-tier suppliers of materials, components or services, when the customer flows the requirement down.
• Contract manufacturers and machine shops producing parts to a customer drawing or specification.

The requirement is contractual. GM customer-specific requirements, for example, require compliance with AIAG PPAP and GM quality requirements. FCA US customer-specific requirements require PPAP and describe evidence of design and process conformity.

The main requirements are evidence of production-representative parts, documented process controls, and a signed submission at the level the customer specifies.

• Document product, process, inspection and test evidence.
• Support customer-specific OEM requirements.
• Provide contractual supplier evidence.
• Use production materials, tooling, equipment, operators and process conditions for production-run PPAP.
• Meet every drawing characteristic at its specified nominal and tolerance.
• Run process capability studies to customer-specific thresholds.
• Validate at the quoted production rate.
• Submit the signed Part Submission Warrant.

Submission level is set by the customer. Levels 1 and 2 are reduced submissions, Level 3 is a full submission of records and sample evidence, Level 4 is customer-defined, and Level 5 retains records onsite for customer review.

PPAP affects sourcing because it gates production release. A part cannot ship to an automotive customer at volume until the required submission is approved.

• Timing: approval work sits between tooling and volume production, so it must be planned into the launch schedule.
• Cost: dimensional layouts, capability studies, material testing and documentation consume supplier engineering time.
• Supplier selection: a supplier's ability to produce and retain PPAP evidence is a practical qualification criterion.
• Change control: design, material, tooling, location or process changes may require customer approval before the change is implemented.
• Risk: weak evidence surfaces late, often as launch delays or containment at the customer.

For buyers, the practical question is not whether a supplier can make one good sample. It is whether the supplier can document and repeat the process at the quoted production rate.

Suppliers get PPAP approval by building production-representative parts, documenting the process and submitting the required evidence at the customer-specified level.

1. Confirm the customer requirement Identify the applicable customer-specific requirement and the required submission level for the part. The customer defines the level.
2. Plan the process Develop the process flow, PFMEA and control plan that describe how the part will be made and controlled in production.
3. Build production-representative samples Use production materials, tooling, equipment, operators and process conditions so the evidence reflects real production.
4. Inspect, test and study Complete dimensional results, material and performance testing, measurement system analysis and process capability studies.
5. Submit and close out Assemble the records, submit the signed Part Submission Warrant, and respond to any customer questions or corrective actions.

The path is evidence-based rather than certificate-based. There is no standalone PPAP certificate. Approval is granted by the customer for a specific part and process.

Typical PPAP documents cover design records, process planning, measurement and test results, and the final warrant. What is actually submitted depends on the level.

Audits and reviews vary by level. Level 5 retains records onsite for customer review, so approval timing depends on audit access. Reduced levels submit a customer-defined subset, but the customer may still require retained records.

Material evidence uses the customer-approved grade rather than a universal PPAP material. Production samples must be made with approved production tools, materials, equipment and process conditions.

Most PPAP confusion comes from treating it as a certificate, a one-time event, or a paperwork exercise. It is none of those.

Two related terms are also often mixed up. An ISIR is an initial-sample inspection report, while PPAP is a broader evidence package and approval process. A control plan defines production controls; PPAP submits it with other records as evidence of readiness.

SR handles PPAP requirements as a manufacturing broker: we collect quotes from a vetted supplier network, manage quality and inspection, and deliver parts. We do not own factories or machines.

• We collect quotes from suppliers in our vetted network against your drawing and specification.
• We confirm the PPAP requirement and submission level you need before production is scheduled.
• We manage quality and inspection activity so evidence is produced alongside the parts.
• We coordinate documentation and inspection records through delivery.
• Quote turnaround is typically 5-7 working days.

Approval is granted by your customer to the producing supplier for a specific part and process. Our role is to source, coordinate and verify.