Mastering PPAP: Aiming for Six Sigma Precision

Last Updated on 13 September 2023

Today, let’s dive deeper into the Lean Six Sigma knowledge pool and explore an indispensable tool for efficient and consistent production – the Production Part Approval Process (PPAP). The PPAP is a strategy of immense value to anyone in a production role, particularly those implementing Six Sigma methodologies.

Unmasking the PPAP

In the world of manufacturing and production, standards, consistency, and quality walk hand in hand. The Production Part Approval Process (PPAP) is a standardized procedure in the automotive and aerospace industries that helps manufacturers and suppliers communicate and approve production designs and processes before, during, and after manufacture.

The process ensures that the manufacturers interpret the design recorded correctly and can deliver parts that meet quality standards consistently.

The Components of the PPAP

Usually, the PPAP is composed of 18 elements, which tie into five levels of submission to the customer. These elements range from design documentation and authorization, to customer engineering approval, process flow diagram, process failure mode and effects analysis (PFMEA), control plan, to measurement system analysis studies (MSA), sample parts, and more. The 18 elements are:

1. Design Records and Documentation
2. Authorized Engineering Change Documents
3. Engineering Approval, if applicable
4. DFMEA (Design Failure Mode and Effects Analysis)
5. Process Flow Diagram
6. PFMEA (Process Failure Mode and Effects Analysis)
7. Control Plan
8. Measurement System Analysis Studies (MSA)
9. Dimensional Results
10. Records of Material, Performance Tests
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR) for Appearance items, if applicable
14. Sample Production Parts
15. Master Samples
16. Checking Aids
17. Customer-Specific Requirements and Submissions, if applicable
18. Part Submission Warrant (PSW)

Elements required at each submission level

There are five different submission levels in PPAP. The Production Part Approval Process (PPAP) elements required at each of the five submission levels are detailed as follows:

1. Level 1:
   • Part Submission Warrant (PSW)
2. Level 2:
   • Part Submission Warrant (PSW)
   • Product Samples
   • Limited Supporting Data (usually includes the following elements):
     • Design Records and Documentation
     • Material and Performance Test Results where applicable
     • Dimensional Data for Selected Samples
     • Process Flow Diagram, PFMEA, and Control Plan
3. Level 3:
   • Part Submission Warrant (PSW)
   • Product Samples
   • Complete Supporting Data (all 18 elements, as applicable):
     • Design Records and Documentation
     • Authorized Engineering Change Documents
     • Engineering Approval if applicable
     • DFMEA
     • Process Flow Diagram
     • PFMEA
     • Control Plan
     • Measurement System Analysis Studies (MSA)
     • Dimensional Results
     • Records of Material, Performance Tests
     • Initial Process Studies
     • Qualified Laboratory Documentation
     • Appearance Approval Report (AAR) for Appearance items if applicable
     • Sample Production Parts
     • Master Samples
     • Checking Aids
     • Customer-Specific Requirements and Submissions if applicable
     • Part Submission Warrant (PSW)
4. Level 4:
   • Part Submission Warrant (PSW)
   • Other Requirements as Defined by the Customer. An individualized list provided by the client that may include a mix of the available 18 elements, but not representing the full set.
5. Level 5:
   • Part Submission Warrant (PSW)
   • Product Samples
   • Complete Supporting Data (all 18 elements, as applicable) available for review at the supplier’s manufacturing location.

It’s important to note that Level 4’s requirements can vary significantly based on the elements requested by the customer.

How PPAP Adds Precision to Six Sigma

As a Six Sigma Ninja, accuracy, process efficiency, and quality are our prime targets. Here’s how the PPAP fits into this purpose:

• Enhanced Supplier Performance: The PPAP ensures suppliers meet the manufacturer’s specifications, decreasing variation.
• Reduced Waste: With thorough pre-production testing, there’s less chance of waste from defective parts.
• Improved Quality: The PPAP improves product quality by validating production processes and components.
• Better Customer Satisfaction: When the final product meets or exceeds expectations, customer satisfaction levels soar.

In this ever-evolving manufacturing landscape, the PPAP provides solid ground with its standardized processes and stringent quality requirements.