Conquering PPAP Level 5 Submission: A Flawless Guide

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.

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.