Production Part Approval Process is a collaborative method that employs proven tools and techniques to systematically minimize risks before a product or service is launched. Initially developed by AIAG (Automotive Industry Action Group) in 1993 with input from the “Big Three” automakers – Ford, Chrysler, and GM – PPAP has since expanded beyond the automotive industry to many others. It controls changes and ensures product conformity, thereby enhancing customer satisfaction.
The main goal of PPAP is to confirm that the organization fully understands the customer’s engineering design records and specifications, and that the manufacturing process can consistently produce parts that meet these requirements during a live production run at the quoted rate. PPAP outlines general requirements for production part approval, including production and bulk materials.
PPAP is essential for three key reasons:
1.It allows customers (the OEM) to validate that the supplier’s process can consistently deliver products at the required quality and quantity under normal production conditions.
2.It helps suppliers thoroughly understand the customer’s product requirements and specifications.
3.It ensures both customers and suppliers have aligned, documented expectations.
The manufacturing sector is highly competitive, where reducing costs, speeding up time to market, and maintaining or improving quality are crucial for success. Achieving quality early in the lifecycle and addressing issues quickly saves significantly more time and money compared to rework, repairs, or scrapping parts. The goal for every OEM is to have a reliable, repeatable process, and PPAP helps enforce that standard.
Benefits of PPAP Submissions
• Maintains design integrity.
• Identifies issues early for prompt resolution.
• Reduces costs associated with poor quality and warranty claims.
• Helps manage supplier changes.
• Prevents the use of unapproved or nonconforming parts.
• Highlights suppliers that require further development.
• Improves customer satisfaction and overall product quality.
A robust Production Part Approval Process (PPAP) is vital for success as it ensures parts are consistently produced to meet quality standards and customer specifications. This process mitigates risks, minimizes the need for corrective actions, and fosters clear communication between suppliers and manufacturers. By validating the production process, PPAP promotes high-quality output, enhances reliability, and strengthens trust, resulting in smoother operations and increased customer satisfaction.
