A PPAP submission is the package of evidence a supplier sends to show it can make your part correctly and consistently at production rate. The Production Part Approval Process manual from the AIAG defines five submission levels, from a single signed warrant up to a full file reviewed at the plant.
For a general introduction to PPAP and how Indian suppliers use it, read what PPAP is. This article covers what goes in a submission and how to choose a level.
The five levels
- Level 1: the Part Submission Warrant only, plus an appearance approval report for appearance items.
- Level 2: the warrant with product samples and limited supporting data.
- Level 3: the warrant with product samples and complete supporting data. This is the default if the customer does not say otherwise.
- Level 4: the warrant and other requirements defined by the customer.
- Level 5: the warrant with product samples and complete supporting data, reviewed at the supplier's plant.
What a full file contains
The AIAG manual lists 18 elements. The supplier keeps all of them on file, and the level decides which ones it sends to you. The main ones are:
- Design records, such as the drawing, and any approved engineering change documents.
- The process flow diagram, process FMEA and control plan, explained in control plans and PFMEA.
- Measurement system analysis showing that gauges are fit for the tolerance.
- Dimensional results for every characteristic on the drawing, on parts from a production run.
- Material and performance test results from a qualified laboratory.
- Initial process studies, such as capability studies on key characteristics.
- Sample parts, a master sample and any checking aids.
- The Part Submission Warrant, which summarises the result and is signed by the supplier.
How to choose a level
Use Level 3 for new parts, new suppliers and safety or fit-critical parts. Use Level 1 or 2 for simple parts, repeat parts or minor changes from a proven supplier. Use Level 5 when you want to see the evidence on the shop floor, which is common for critical parts.
Write the level into your purchase order or supplier agreement. If you do not, you may get only a warrant. German customers may ask for the VDA production process and product approval instead, which covers similar ground.
When to resubmit
A new submission is usually needed for a new part, a design change, new tooling, a change of material source, a process change or a move to another site. Make your supplier agree in writing to notify you before any such change.
Next step
We review PPAP files, check the parts and records at the plant and flag gaps before you approve. Book a free sourcing review to plan your part approval.