What is PPAP and When Do You Need It?

If you’re a manufacturer of parts in the car or aerospace industries, you will be familiar with the industry standard Production Part Approval Process (PPAP). Essential for accurate production processes that help to reduce delays and improves conformance of manufactured parts. Here’s a simple guide to help you understand and streamline your PPAP process.

PPAP, or Production Part Approval Process, is an international standard (ISO/TS 16949) that sets out standardised design principles, manufacturing processes and quality checks so manufacturers and suppliers can speak the same language. 

PPAP approval only applies to new or modified parts. You won’t need to seek approval for the same component twice unless you undertake redesign or extensive modifications. However, the necessity of PPAP approval does require a more extensive planning, design and inspection process when rolling out a new part for the first time. There are two ways you can approach PPAP approval. You can either go through the process in-house with your own team, or you can outsource the process to an inspection agency such as Status Metrology.

Two Ways to Handle PPAP Approval

In-House: Your team takes care of the whole process. This can be challenging for mid-sized manufacturers with busy schedules. Although handling PPAP in-house can give you direct control over the process, it can also stretch your resources thinly, especially if your team is already juggling multiple tasks.

Outsource: Partner with an inspection agency like Status Metrology that can handle the PPAP process, so your team can focus on what they do best – keeping production running smoothly. Outsourcing can save time and reduce stress, allowing experts to manage the complexities of PPAP while you concentrate on your core operations.

PPAP Approval Checklist

Working with a company like ours can streamline this process, using a PPAP Approval Checklist can significantly enhance clarity and efficiency. Below are two simple checklists tailored for the automotive and aerospace industries, which will help you quickly assess your resources and determine if you can manage the process internally or if external support is needed.

For Aerospace Components:

• Purchase order and demand fulfilment contract: Start with the basics and ensure you have all your order details and contractual agreements to hand.
• Technical production drawings or change documents: Have precise technical drawings or modification documents ready to go.
• Engineering approval documents from your customer: Get the necessary engineering approvals to confirm that your designs meet customer specifications.
• Failure Mode and Effect Analysis (FMEA) documents for design and process: Identify potential failure points and their impact on your design and process.
• Flow diagrams outlining your process: Map out your production process clearly to highlight each step involved.
• Production Verification Testing (PVT) strategy: Outline how you’ll verify the production process and ensure it meets quality standards.
• Approval details for manufacturing and testing processes: Document the approval criteria for your manufacturing and testing stages.
• Material certification documents: Gather certifications for all materials used in your components.
• Quality control strategy: Develop a robust strategy to maintain high-quality standards throughout production.
• Approval for raw materials: Ensure all raw materials are approved for use in your production.
• Approval for product appearance, packaging, labelling, and transport: Make sure the final product meets all appearance, packaging, labelling, and transport requirements.

For Automotive Parts:

• Full design records: Ensure all drawings, specifications, and design records are up to date and confirm that any engineering changes have been approved.
• Measurement Systems Analysis (MSA) report: Review the MSA to verify that measurement systems are capable and accurate.
• Material performance reports: Document how materials perform under various conditions.
• Sample product process studies and analysis: Confirm sample production parts have been produced and submitted for approval.
• Analysis: Provide detailed analysis of sample products to showcase their compliance with standards.
• Analysis of checking aids (e.g., CMM’s): Ensure all checking aids are analysed and approved for use.
• Approved laboratory documents (if applicable): Include documentation from approved laboratories if needed.
• Proof of compliance records: Maintain records proving compliance with all relevant standards and regulations.
• Part Submission Warrant (PSW) for each component: Submit a Part Submission Warrant for every component to confirm that all requirements are met.

How to Avoid Inspection Bottlenecks

PPAP approval can sometimes slow things down due to the back-and-forth nature of the process. But here’s how you can avoid potential delays:

• Plan Ahead: Effective planning is key. Make sure you have all your documentation ready and organised.
• Manage Resources Smartly: Allocate resources efficiently to ensure that every step of the PPAP process is covered without overloading your team.
• Partner with Experts: Consider working with third-party inspection services to handle the approval process. This can save time and reduce stress.

By following this guide, you can make the PPAP approval process smoother and keep your production line efficient. Reducing delays and streamlining the process helps in getting parts approved faster, maintaining productivity. A streamlined PPAP process leads to satisfied customers, lower costs, and a more successful business. 

How can we help? Get in touch with our team.