The Production Part Approval Process (PPAP) is the cornerstone of quality control in the automotive and aerospace industries.  Level 5, the most demanding level, ensures complete documentation and on-site verifiability for critical parts.  This article equips you, the supplier, for a smooth PPAP Level 5 submission, guaranteeing customer confidence and a successful project launch.

Understanding PPAP Level 5 Submission requirements

First of all, it’s important to understand the differences between PPAP levels. For example, PPAP Level 3 requires submitting a Part Submission Warrant (PSW) with product samples and all supporting documentation, while a PPAP Level 5 requires the same documentation, but with an additional on-site review at the supplier’s manufacturing facility, meaning the customer can directly inspect the production process and verify the quality of the parts being made; essentially, Level 5 is a more rigorous process with a higher level of scrutiny compared to Level 3.

PPAP Level 5 Submission signifies a comprehensive PPAP package containing all 18 elements outlined by the AIAG (Automotive Industry Action Group).  While the specific documents requested may vary based on customer specifications, a solid understanding of the core elements is essential:

1. Part Submission Warrant (PSW): This document acts as the official cover sheet, summarizing the submitted documents and requesting customer approval.
2. Design Records: These documents provide a detailed history of the part’s design, including engineering drawings, material specifications, and any design changes.
3. Process Flow Diagrams: These charts visually depict the entire production process, highlighting key steps, control points, and potential failure modes.
4. Control Plans: These plans detail the inspection methods and procedures used to ensure parts meet all dimensional and quality specifications.
5. Measurement System Analysis Reports (MSA): These reports demonstrate the accuracy and repeatability of the measuring equipment used for quality control.
6. Dimensional Results: This section provides documented measurements of the produced parts, verifying adherence to the specified tolerances.
7. Material Test Reports: These reports showcase the results of tests conducted on the materials used in the part, confirming they meet the required properties.
8. Initial Sample Inspection Report (ISIR): This report details the results of the initial inspection of the produced parts, comparing them against the specifications.
9. Appearance Sample Approval Report (if applicable): This report documents the customer’s approval of the part’s visual characteristics, such as color, finish, and texture.
10. Customer Engineering Approval (if applicable): This document confirms the customer’s acceptance of any deviations from the original design specifications.
11. Record of Waiver (if applicable): This document details any specific requirements waived by the customer and the justification for such waivers.
12. Simulation Studies (if applicable): This section includes any simulations or analyses conducted to predict the part’s performance under various conditions.
13. Manufacturing Location Layout: This provides a physical layout of the manufacturing facility where the parts are produced.
14. Material Certification: Documents verifying the material properties and composition used in the part’s production.
15. Customer Specific Requirements: Any additional documents or data specifically requested by the customer.
16. Process FMEA (Failure Mode and Effects Analysis): This analysis identifies potential failure modes in the production process and outlines mitigation strategies.
17. PFMEA Results: This section details the results of the process FMEA, including the severity, occurrence, and detectability of potential failures.
18. Corrective Action Report (if applicable): This report documents any corrective actions taken to address identified issues during the production process.

Building a Winning Strategy

Early preparation is key to a successful PPAP Level 5 submission. Here are crucial steps to follow:

• Gather Requirements: Obtain a clear understanding of the customer’s expectations. Review the purchase order, drawings, and any additional quality specifications provided.
• Cross-Functional Team Formation: Assemble a team comprising representatives from engineering, quality control, production, and documentation departments. This ensures clear communication and a holistic approach.
• Documentation Review: Thoroughly review all existing documentation related to the part and the production process. Ensure completeness and accuracy.
• Gap Analysis: Identify any missing documents or areas where additional data is required to fulfill all Level 5 requirements.
• Develop Missing Documents: Focus on creating any missing documents, such as control plans, measurement system analysis reports, and process flow diagrams.
• Data Collection & Analysis: Gather and document the necessary data points, including dimensional results, material test reports, and initial sample inspection results.
• Customer Communication: Maintain consistent communication with the customer throughout the process. Address any questions or concerns promptly.

Streamlining the Process

Several practices can enhance efficiency and streamline the PPAP Level 5 submission process:

• Utilize Templates: Leverage readily available PPAP templates to expedite document creation. Many industry organizations provide standardized templates.
• Electronic Documentation: Utilize electronic document management systems to store and access PPAP documents efficiently, just as PPAP Manager by Kiuey.
• Training & Awareness: Provide training to relevant personnel on PPAP requirements and proper documentation procedures.
• Internal Audits: Conduct regular internal audits to proactively identify and address any potential gaps in documentation or quality control procedures.
• Continuous Improvement: Embrace a culture of continuous improvement within your organization. Regularly review and update PPAP procedures to reflect best practices and changing customer requirements.

The Power of Collaboration

A successful PPAP Level 5 submission hinges on effective collaboration between the supplier and the customer. Here are some key points to remember:

• Open Communication: Maintain open communication channels with the customer throughout the process. Provide timely updates and address any concerns promptly.
• Customer Involvement: Encourage customer participation during the development and review of PPAP documents. This ensures alignment with their expectations.
• Joint Problem-Solving: Approach any challenges or discrepancies with a collaborative problem-solving mindset. Focus on finding mutually agreeable solutions.

Conclusion

A meticulous PPAP Level 5 submission demonstrates your commitment to quality and process excellence. By following the outlined steps, building a robust preparation strategy, and fostering strong customer relationships, you can ensure a smooth submission process and lay the foundation for a successful long-term partnership with your customer.  Remember, a well-documented and verified Level 5 PPAP submission instills confidence in your capabilities, paving the way for a successful project launch and a thriving business relationship.