Understanding the Production Part Approval Process (PPAP)

Industries around the world are facing the same big challenge – more than half of all the resources used are wasted. It’s never been more important for the production process to be more efficient.

Strict standards like FDA approval and ISO certification can help different sectors ensure product safety and effectiveness. Manufacturing also needs a system to handle critical tasks and enable suppliers and customers to work together.

Here’s where the Production Part Approval Process (PPAP) comes in. This method standardizes the parts supplied by manufacturers to meet all customer requirements and ensure quality standards.

Learn more about PPAP so you know what to expect. Whether you’re a supplier or a customer, knowing how to implement a reliable system makes all the difference.

What is the Production Part Approval Process (PPAP)?

The Production Part Approval Process is a standardized procedure used in manufacturing to ensure components produced by suppliers always meet customer requirements. This process lets suppliers show they have the necessary systems and controls to produce parts that consistently meet standards.

PPAP has become a key tool across various industries to improve quality control in safety critical applications. With a PPAP package, suppliers can provide clear documentation that they have met or even exceeded customer requirements and that their processes are reliable.

Looking to modernize your LCDs?

Benefits of PPAP

Implementing PPAP can do a lot for your business. Here are some notable ones.

• Makes sure that suppliers have the right processes ready to produce parts consistently and reduce defects.
• There’s clear communication for setting expectations and resolving potential issues more effectively.
• Suppliers can identify and eliminate inefficiencies in their production processes to reduce waste and lower production costs.
• Having reliable quality assurance systems builds trust and strengthens supplier-customer relationships.
• This standardization helps suppliers be competitive in the global market, guaranteeing that their parts meet international standards.

With PPAP, manufacturers can achieve a much higher level of quality control while still being able to reduce costs and enhance their overall efficiency. 

Five PPAP Levels of Submission

A PPAP can be required for any submission of a new part or when changes are made to an existing process. The customer can request a PPAP at any stage of the product’s life, so the supplier must have a quality system to document all PPAP requirements at all times.

PPAP involves many things to ensure production needs are met, but not all of these elements need to be completed to be verified. The specific requirements are usually negotiated during the quoting process.

The PPAP report has five levels of submission – Level 3 being the default for approval.

• Level 1: Submission of the Part Submission Warrant (PSW) only.
• Level 2: Submission of the PSW along with product samples and limited supporting data.
• Level 3: Submission of the PSW along with product samples and complete supporting data. This is the default level of PPAP submission approval.
• Level 4: Submission of the PSW and other requirements as defined by the customer.
• Level 5: Submission of the PSW along with product samples and complete supporting data, which are available for review at the supplier’s manufacturing location.

Each level has different degrees of documentation and verification to meet customer requirements. These allow customers and projects to be flexible based on what they need. 

Looking to modernize your LCDs?

The 18 Elements of PPAP

The PPAP system consists of 18 essential elements that serve as a comprehensive framework for quality assurance, covering everything from the design process to production samples.

Understanding these elements is important for both suppliers and customers to maintain high standards and efficient processes. 

1. Design Documentation

Includes copies of both customer and supplier drawings, a copy of the purchase order, and sometimes even documentation of material composition.

2. Engineering Change Notice

If there are any design changes, this notice must be included so you can inform the customer of the adjustments and their impact on production. 

3. Customer Engineering Approval

This provides solid evidence that the customer’s engineering department has approved the part.

4. Design Failure Mode and Effects Analysis (DFMEA)

Identifies the possibilities of failure in the design of the part and assesses their effects to minimize these risks and maximize reliability.

5. Process Flow Diagram

This is a graphical representation that outlines basically every step in the part’s production process. This makes sure that everything’s clear and that there’s a proper sequence in the operation. 

6. Process Failure Mode and Effects Analysis (PFMEA)

Much like the DFMEA, the PFMEA identifies potential failures in the production process and also provides outlines of what to do to avoid these risks.

7. Control Plan

Based on the PFMEA, this should be able to list all the product characteristics and inspection methods to maintain a consistent quality.

8. Measurement System Analysis (MSA)

This includes studies like “Gage Repeatability & Reproducibility (GR&R),” a method for measuring the accuracy of gauging instruments, so that the equipment used in production is reliable.

9. Dimensional Results

These are the measurements of the sample parts compared to design specifications, recorded and verified as needed.

10. Design Verification Plan and Report (DVP&R)

Summarizes all material and performance tests that have been conducted. Results and methodologies should be described here in detail.

11. Initial Process Studies

Statistical Process Control (SPC) charts and other assessment methods of various critical processes aimed at maintaining stability and performing as intended. 

12. Qualified Laboratory Documentation

This mentions the certifications of any laboratories involved in the testing stage. Testing might be done in-house or in off-site facilities. 

13. Appearance Approval Report (AAR)

Confirms that the final product meets the design criteria – including the color, texture, and fit.

14. Sample Production Parts

These are actual parts that are sent to the customer for approval, which are then documented and stored for reference.

15. Master Sample

This is the final, approved sample that’s used as a benchmark for future production.

16. Checking Aids

Describes all the tools used for inspection, testing, or measurement during production. This includes their descriptions and calibration schedules.

17. Customer Specific Requirements

Any additional requirements specified by the customer for the PPAP process.

18. Part Submission Warrant

This is a detailed summary document of the entire PPAP package. It is required for each part number unless the customer says otherwise. 

Looking to modernize your LCDs?

Effective PPAP Starts with the Right Manufacturer

The Production Part Approval Process maintains quality and consistency in manufacturing. Adopting PPAP builds strong supplier-customer relationships, enhances production processes, and makes things better overall.

With PPAP comes choosing your manufacturer. For example, in LCD production, an experienced manufacturer ensures all your requirements are met. They have the certifications and standards that guarantee excellent services right from the start.

Partnering with an experienced LCD manufacturer who understands PPAP streamlines your production and reduces errors, helping you meet quality expectations and succeed in a competitive market.