Production Part Approval Process — Educational Guide
Special Processes Institute · sp-i.org ·
PPAP Knowledge Guide
Understand why Production Part Approval Process exists, when approval is required, how the submission levels work, what evidence belongs in a robust package and how automotive PPAP relates to aerospace APQP, FAIR and production readiness.
18Common AIAG PPAP elements
5Submission levels
3Typical dispositions
0%Learning checklist complete
What PPAP Demonstrates
PPAP is a formal approval process used to demonstrate that the organisation understands the applicable engineering design record and specification requirements and that the intended production process can repeatedly produce conforming product during an actual production run at the required rate.
PPAP approves evidence about a defined production configuration. It is not simply approval of a sample part, an inspection report or a document pack.
PPAP should answer four questions:
- Do we understand every applicable requirement?
- Is the product definition correctly translated into the process?
- Are production controls effective and measurement systems suitable?
- Can the process repeatedly meet requirements under production conditions?
PPAP Process Flow
Confirm trigger & customer rules
Freeze submission configuration
Run production-intent trial
Collect objective evidence
Review package internally
Submit to customer
Receive disposition & control change
Why PPAP Is Required
Requirement understanding
Confirms drawings, specifications, changes, customer requirements and acceptance criteria are understood.
Confirms drawings, specifications, changes, customer requirements and acceptance criteria are understood.
Production evidence
Uses production-intent people, material, tooling, equipment, methods, software, suppliers and rate.
Uses production-intent people, material, tooling, equipment, methods, software, suppliers and rate.
Risk control
Links process flow, PFMEA, control plan, measurement and capability evidence.
Links process flow, PFMEA, control plan, measurement and capability evidence.
Customer authorisation
Provides the defined submission evidence and a formal customer disposition.
Provides the defined submission evidence and a formal customer disposition.
Configuration baseline
Identifies the approved product and process state against which future changes are assessed.
Identifies the approved product and process state against which future changes are assessed.
Launch confidence
Reduces nonconformance, disruption, warranty, escape and late-change risk.
Reduces nonconformance, disruption, warranty, escape and late-change risk.
Approval Status
Approved
The submission satisfies customer requirements and product may be supplied subject to the authorised conditions and schedule.
The submission satisfies customer requirements and product may be supplied subject to the authorised conditions and schedule.
Interim / conditional approval
Time- or quantity-limited authorisation with defined outstanding actions. It is not permanent approval.
Time- or quantity-limited authorisation with defined outstanding actions. It is not permanent approval.
Rejected
The package or product/process evidence is unacceptable. Corrective action and resubmission are required before authorised supply.
The package or product/process evidence is unacceptable. Corrective action and resubmission are required before authorised supply.
The 18 Common PPAP Elements
Applicability, retention and submission are defined by the customer and the controlled PPAP manual. “Not submitted” does not mean “not required.” Search or filter the learning cards below.
Important corrections to common summaries: DFMEA applies where the supplier is design-responsible; customer-specific requirements are normally the eighteenth AIAG element; special-process certificates usually support material/performance evidence and customer-specific requirements rather than replacing the standard element structure.
Submission Levels
Select a level to see what is normally submitted. The supplier still retains and maintains all applicable PPAP evidence unless the customer states otherwise.
When New or Revised Approval May Be Required
Always confirm the exact customer notification and submission rules before implementing a change.
Production Run Conditions
A credible PPAP trial should represent the intended production system. The required quantity, duration and rate are customer-defined. Record any departure and evaluate whether it limits the validity of the evidence.
Production material and approved sources
Production tooling, gauges and equipment
Normal operators and work instructions
Intended facility, layout and software
Planned production rate and cycle
Normal inspection, handling and packaging
Automotive PPAP and Aerospace PPAP
| Topic | AIAG automotive context | Aerospace context |
|---|---|---|
| Primary reference | AIAG PPAP manual plus customer-specific requirements. | AS9145 where contractually invoked, integrated with applicable 9100-series and customer requirements. |
| Lifecycle relationship | PPAP is the approval output supported by APQP and the core tools. | AS9145 establishes APQP and PPAP requirements; PPAP confirms completion of product and process validation outputs. |
| FAIR relationship | Dimensional and design-record evidence may be structured differently by the customer. | AS9102 FAI verifies the first production process against the design definition. It is complementary to APQP/PPAP, not a replacement for process-risk, capability, MSA and production-readiness evidence. |
| Characteristics | Special characteristics are linked through design/process risk and the control plan. | Key characteristics and variation-management requirements may invoke AS9103 and customer-specific controls. |
| Special processes | Evidence supports applicable specifications and customer requirements. | Source approval, qualification, personnel, validation, periodic testing, certification and traceability can be critical PPAP evidence. |
PPAP Is Broader Than FAIR
FAIR primarily asks:
Does the first production article and its documented production process account for and satisfy the complete design definition?
Does the first production article and its documented production process account for and satisfy the complete design definition?
PPAP additionally asks:
Is the production system sufficiently understood, controlled, measured, capable and ready to repeatedly produce conforming product?
Is the production system sufficiently understood, controlled, measured, capable and ready to repeatedly produce conforming product?
Capability and Acceptance Criteria
Do not treat a generic Cpk value as universally sufficient. Required indices, study design, minimum sample size, stability expectations and reaction plans must come from the customer, characteristic classification and applicable standard. Capability indices are meaningful only when the data and process satisfy the method’s assumptions.
Never hide an unstable process behind a capability number. Investigate special causes, confirm measurement adequacy and use the customer’s defined response where acceptance criteria are not met.
PPAP Learning Readiness Check
This is an educational self-check, not a customer approval record. Tick an item when you understand why the evidence matters.
Internal Review Before Submission
Configuration
- Correct drawing and specification revision
- All authorised changes included
- Part, process, tooling and site match trial evidence
- Documents share consistent identifiers and dates
Linkage
- Flow, PFMEA and control plan align
- Characteristics map to inspection and results
- PFMEA actions are implemented
- Reaction plans address loss of control
Evidence quality
- MSA supports measurement decisions
- Capability uses suitable stable data
- Laboratory scope and reports are acceptable
- Certificates trace to the production lot
Submission control
- Customer level and forms confirmed
- Exceptions and open actions are transparent
- PSW data match supporting evidence
- Internal authorised approval completed
PPAP Knowledge Check
Select an answer to begin.
Standards and Authoritative Resources
| Resource | Use |
|---|---|
| AIAG PPAP, 4th Edition | Defines the automotive Production Part Approval Process, submission requirements, customer notification and submission levels. |
| AIAG APQP, 3rd Edition | Current APQP guidance, including gated programme management, sourcing, change management, metrics, risk mitigation and traceability. |
| AIAG Control Plan, 1st Edition | Standalone control-plan guidance linked to APQP, FMEA and production controls. |
| SAE AS9145 | Aerospace-series requirements for performing and documenting APQP and PPAP. |
| SAE AS9102C | Requirements for performing and documenting aerospace First Article Inspection. |
| SAE AS9103 | Variation-management guidance for key characteristics where applicable. |
| AS9100 / EN 9100 | Broader aerospace QMS requirements for operational planning, design, production, external providers, verification and change. |
| IATF 16949 and customer-specific requirements | Automotive QMS and customer rules that determine exact PPAP applicability, forms, evidence, timing, retention and approval. |
Controlled-source warning: This app is educational and does not reproduce copyrighted standards or replace customer instructions. Verify the current revision, contractual flow-down, customer-specific requirements and approved forms.
Key Learning Summary
- PPAP provides evidence about a defined production configuration and its ability to meet requirements consistently.
- The submission level controls what is sent or made available—not which applicable work must be performed.
- Production-intent evidence must represent the process the customer is being asked to approve.
- Consistency among the design record, process flow, PFMEA, control plan, measurement and results is essential.
- Customer approval is not permission to make uncontrolled changes.
- In aerospace, FAIR and PPAP are complementary when both are required.
Special Processes Institute · sp-i.orgPPAP Knowledge Guide