The ‘Design Records’ could be a drawing of the part.

This is normally provided

Design Records by the customer because they are the ones who would normally design the part
and understand its end use.
A print copy of the drawing or design record should be sent along with the
PPAP for the following reasons:
Shows the customer you have a copy of the part drawing
Shows the customer that you have the correct part drawing
Makes sure that both you as the suppler and the customer are discussing the
same part
These design drawings should include the following:
Each and every feature must be “ballooned” or “road mapped” to correspond
with the inspection results (including print notes, standard tolerance notes and
specifications, and anything else relevant to the design of the part).
They could also include any functional / material / test specifications that the
customer requires.

The ‘Engineering Change Documents’ section should include any marked and
Authorized signed drawings specifications etc. that state or authorize the supplier to deviate
Engineering or change any part of the instructions from the design record (normal signed by
a customer engineer or VIP). You should also include any Applicable
Change Engineering Permit(s) and any extra comments that relate to deviation of design
or engineering changes. If the Supplier PPAP submission includes changes
referenced on a submitted Supplier Change Request (SCR) form, then copies of
the approved SCR must be included in this section of the PPAP.

Engineering The Customer Engineering Approval section is relatively new and was included
in the latest AIAG PPAP. It includes any documents relating to temporary
Approval deviation and any supporting evidence of parts sent to the customer before the
PPAP.

DFMEA Please note that this is only applicable when the supplier has the design
responsibility.
Design Failure Mode and Effects Analysis (DFMEA) is an application of the
Failure Mode and Effects Analysis (FEMA) principles but is specifically aimed
at the design stage of the process. The basic concept of the DFMEA is to
understand where the product design could fail. The DFMEA method allows the
design team to document what they know and suspect about a product’s failure
modes prior to completing the design, and then use this information to design
out or mitigate the causes of failure.
Ideally, the DFMEA is begun at the earliest stages of concept development, and
can then be used to help winnow down competing designs and generate new,
more robust concepts.

Process Flow Process Flow Diagram, also known as a process flow chart, shows the document
and clarifies all steps required in the manufacturing of the part in question. The
Diagram process flow diagram must match both the control plan and the Process Failure
Mode and Effects Analysis (PFEMA). The process flow diagram must include
all of the main steps in the processing of the part and also all offline activities
such as handling, measuring, inspection etc. The diagram also needs to show the
flow of non-conforming materials (rejects), parts that can be salvaged, and parts
that can be waste or scrap from the product.
PFMEA The PPAP must include a PFMEA (Process Failure Mode and Effects Analysis)
that considers all the possible failures of the production process for the part in
question. When the PFEMA has been created it becomes a living document and
is maintained throughout the entire life cycle of the part.
PFMEA evaluates each process step and assigns a score on a scale of 1 to 10 for
severity, occurrence, and detection, which then gives you a RPN (Risk Priority
Number). The idea of a PFEMA is that it will show you areas in which the
production of the part can break down. In turn this can allow you to update the
process to make it more robust and understand causes when failure occurs.

Control Plan A control plan of the process should be included in your PPAP submission. It
should mirror the PFEMA and be signed by the relevant parties. You may want
to include areas such as early production containment. This area can also be seen
as a Pre-Launch Control Plan if the part is completely new or if no relevant

Measurement MSA is a study in itself. However in the PPAP the supplier must demonstrate its
own MSA system and must record all tools and instruments used to measure or
System Analysis check the raw materials and finished parts that are listed in the control plan.
Please note that the supplier’s MSA system should conform to their relevant ISO
Studies (MSA) or TS standard

Dimensional In this section of the PPAP the supplier can record any measurements taken
from the finished part. This will include the size, length, width, angles,
Results thickness and any other measurements specified by the customer or the design
drawing. Make sure each measurement is ticked off to ensure it has passed the
test.
If any parts do not meet the correct specification for a valid reason which could
continue into mass production then the supplier should create an exception
report. This will document any abnormal readings, and these should be
commented on to show why these anomalies have taken place.

Records of This should include a summary of all tests that have been performed on the part
in question. The summary should document any pass or fails that have been
Material / identified. It should be signed off by the customer and the supplier to show that
all the tests that are required have been done and any additional data for the tests
Performance has been submitted.

Tests
Initial Process During the initial process studies stage of the PPAP the customer needs to start
performing internal studies. The supplier needs to complete any customer
Studies required studies. An SPC can be used to demonstrate the processes capability.

If testing is performed in a supplier’s internal lab, they must provide a copy of

Qualified their quality certification. The supplier should also provide documentation from
Laboratory an independent test house or the data from the RAW supplier.

Documentation
Appearance The appearance approval report needs to be included in the PPAP. This is
produced from the appearance approval inspection process. This needs to be
Approval Report signed by the customer and include any other documents or concerns related to
the appearance of the product

Sample A number of pictures can be included of the sample part from the same
production run that has been analysed throughout the PPAP. Also, a picture of
Production Parts any storage area and packing instructions / images can be included in this
section.

A master sample is needed to complete the PPAP. This sample MUST be signed
Master Sample by the customer and the supplier when they are both happy that the sample part
meets all the design requirements and extra customer requirements. This can
then be used as a benchmark for other production runs and help the operators
check their work.
“The organization shall retain a master sample for the same period as the
production part approval records, or (A) until a new master sample is produced
for the same customer part number for customer approval, or (B) where a
master sample is required by the design record, Control Plan or inspection
criteria, as a reference or standard. The master sample shall be identified as
such, and shall show the customer approval date on the sample. The
organization shall retain a master sample for each position of a multiple cavity
die, mould, tool or pattern, or production process unless otherwise specified by
the customer.”

Checking Aids When special tools are used they should be photographed, documented and
included in this section, and this should also include the calibration records of
the tools and the dimensional report from the tools

Customer- Each customer may have specific requirements to be included on the PPAP
package. It is a good practice to ask the customer for PPAP expectations before
Specific even quoting for a job. North America auto makers OEM (Original Equipment
Manufacturer) requirements are listed on the IATF website.
Requirements
Part
The Part Submission Warrant or PSW is a document that summaries the whole
‘PPAP Package’. It needs to include details such as:
1) Part Information
Submission Part Name
i. The part name is the parts official name for example Pedal Box or Bonnet
Warrant Locking Platform. This benefits the supplier and the manufacturer by giving the
part a more human name and decreasing the chance of errors for example calling
(PSW) the part QNCA0001450002N could easily be mixed up if multiple PPAPs were
being discussed.
Part Name on Drawing
i. The part name on the drawing is the part ID written or stamped onto the
drawing for example QNCA0001450002N.
Engineering Change Level
i. Will be specified by the manufacturer and could include any manufacturing
change such as tool modifications
Engineering Change Date
i. The date of these changes
Additional Engineering Changes
i. See point C
Additional Engineering Changes Date
i. See point C
Safety and/or Government Regulation
i. Are there any safety and/or government regulation that the supplier and the
manufacturer need to be aware of. These should be listed and relevant
documents included or referred to .
Checking Aid Number
i. ID of any special tools used while completing the PPAP
Checking Aid Engineering Change Level
i. What is the level of the checking equipment you use to check this part are
there any special tools used?
Checking Aid Engineering Change Date
i. Date of the Checking Aid
Customer Part Number
i. The number the customer uses on their system to identify the part. This is
very helpful to know when speaking to different department in the
manufacturers company as not everyone will know the suppliers part number.
Organization Part Number
i. The number the organization uses on their system to identify the part.
Purchase Order Number
i. The ID of the manufacturers purchase order
Weight
i. Weight of the material ordered
2) Suppliers Contact Information
Name of Supplier and/or Vendor Code
Suppliers Address
3) The Customers Contact Information
Customers Name and Division
Any buyer code
4) Materials Reporting
Substance of Concern Information
i. May need to be submitted, Could be COSH data sheets
IMDS format
i. In what format will you submit IMDS or IMDS like information?
IMDS ID
i. What is the module or IMDS number
5) Reason for Submission
There can be many reasons why it is necessary to conduct a PPAP :
i. Initial Submission
ii. Engineering Changes
iii. Tooling: Transfer, Replacement, Refurbishment, or Additional
iv. Correction of Discrepancy
v. Tool Inactive > 1 Year
vi. Change to Optional Construction or Material
vii. Supplier or Material Source Change
viii. Change in Part Processing
ix. Parts Produced at Additional Location
x. Other (Specify)
6) Requested Submission Level
There are different levels of PPAP submission
i. Level 1 – Warrant only submitted to customer
ii. Level 2 – Warrant with product samples and limited supporting data
iii. Level 3 – Warrant with product samples and complete supporting data
iv. Level 4 – Warrant and other requirements as defined by customer
v. Level 5 – Warrant with product samples and complete and complete
supporting data reviewed at suppliers manufacturing location.
7) Submission Results
Have you included results for:
i. Dimensional measurements
ii. Material and function tests
iii. Appearance Criteria
iv. Statistical process package
Do all the results meet all the design requirements with any concerns noted
Mold / Cavity / Production Process ID
8) Declaration
9) Explanations or Comments
Comments / Explanations
Customer tool tags
Signature
Date
Printed name
Phone Number
Fax Number
Job Title
Email
10) Status
Sign off by customer