Optimize production with a PPAP process template

Use a PPAP process template to ensure smooth production

About the Use a PPAP process template to ensure smooth production

This comprehensive PPAP checklist contains detailed questions for each of the 18 production part approval process guidelines, from design reports to part submission warrants. Use this PPAP checklist template to clearly specify the part name, number and PPAP submission level. Capture and store unlimited photos for PPAP documentation, verify PPAP reports such as process flows and complete the PPAP checklist with a digital signature. For documentation covering the entire quality planning process, see our Advanced Product Quality Planning (APQP) checklist.

Make your production thrive with a PPAP checklist template

The 18-step Production Part Approval Process (PPAP) is a set of instructions for suppliers and Original Equipment Manufacturers (OEMs). The PPAP documentation demonstrates that OEMs and suppliers are aware of customer requirements and take steps to make sure that their manufacturing process reliably yields conforming components at the estimated production rate. The status of the production component approval process—fully authorised, interim approval, or rejected—is determined by customers after they have looked over the PPAP documents.

Quality managers use a PPAP checklist to make sure all client requirements are met, produce compliant components, and dispatch them on time. The purpose of the PPAP checklist template is to ensure that each production part meets specific quality standards. This PPAP checklist includes questions about design records, component submission warrants, and more. By using this tool, Quality managers can quickly identify any issues with a production part and correct them before it reaches customer's hands.

Every business needs to take care of its production sector. Checklists can help in maintaining this path, but it's also important to remember that there are three core goals of quality management: improving product quality, reducing waste, and meeting deadlines. The following six steps help achieve these goals:

Plan and execute tests throughout the development process to verify that products meet specified requirements.

Use inspection techniques to find and correct defects before they cause problems during use or impact customer satisfaction.

Verify that parts conform to established engineering standards before releasing them for assembly or manufacturing.

Control communications both internally and with clients through effective communication protocols such as Release Management Plans (RMPs).

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Preview of the template

PPAP Checklist

1. Design Records

Do the design records contain a copy of the drawing to confirm the part or assembly (both producer and customer drawings)?

2. Authorized Engineering Change Documents

Are approved engineering changes applicable?

3. Customer Engineering Approval

Is customer engineering approval required?

4. Design FMEA

Does the FMEA drive Design positive changes as a primary objective?

Have all dimensional tolerances and material properties been admitted?

Does FMEA reflect all major “lessons learned” (such as high warranty, campaigns, etc.) as input to failure mode identification?

Is a statement attached that DFMEA is available to be presented to the customer upon request?

Have customer reliability and guaranty data been used in preparing FMEA?

Have the roots of the problem been defined in terms of something that can be corrected or controlled?

Were attribute characteristics included?

Does FMEA recognise appropriate Special Characteristics contestants, as input to the Special Characteristics selection method?

Are new product introductions and layout changes involved in identifying Special Characteristics?

Does Analysis/Development/Validation (A/D/V) and/or Design Verification Plan and Report (DVP&R) estimate the failure forms from the Design FMEA?

Does FMEA address all high-risk Failure Modes, as recognised by the FMEA team, with executable Action Plans?

Have adequate countermeasures been intended or taken for high-risk numbers?

Were customer plant problems utilised as a deputy in developing the FMEA?

Have customer product problems and/or rejections been involved with countermeasures?

Does submission contain action list from Design Review?

5. Process Flow Diagram Assessment

Does the process layout reflect planning so that a logical flow of material can occur during the manufacturing of the product?

Has the pull system/optimization been considered for this method?

Is the Process Flow Chart in place and identifies all production operations, handling procedures, inspection steps, alternate/back-up processes, and sub-contract suppliers?

Have alternate or back-up processes or sub-contract suppliers been validated?

Are the sequences identified (operation or sequence number) so as to comprehend through to other PPAP documents?

Does the flow chart designating the material flow and check for handling rework and scrap?

Are steps in the process where the product is deposited and/or staged clearly identified?

Does the flow chart show the continuity of production?

Does the flow chart describe how the goods will move, i.e. roller conveyor, slide containers, tubs, etc?

Does the material flow acknowledge potential quality problems due to handling and subcontracting operations?

Does the flow diagram involve all assembly and packaging operations?

Does the flow chart illustrate shipment to the client/consumer and steps to consumption?

Are inspection/quality assurance steps, data recording, attribute checks and/or functional testing involved for each process step?

Is the method flow chart managed, updated and evaluated for completeness?

Does the flow chart recognise in detail all in-house alternate or back-up methods and sub-contract alternate or back-up sources of equipment for products or services provided?

6. Process FMEA

Is there evidence that all print, specification, purchase order, attribute, etc. characteristics are required?

Did proper people participate as part of the FMEA team during the analysis, and are appropriately trained in the procedure?

Are the correct part number, organisation/planning change, and other information documented?

Is a report attached that PFMEA is ready to be presented to the client upon request?

Is Process FMEA integrated and compatible with the Process Flow Diagram, Process Control Plan and other PPAP documents?

Are special controls/actions in place for all Special Characteristics?

Have capability studies been completed to validate the control of the characteristics?

Are quality performance indicators provided as evidence that sufficient methods are in place to monitor and control all characteristics?

Are there measurable quality development projects in place for Special Characteristics?

Is FMEA completed during the “window of opportunity” where it could most efficiently impact the design of the product or process?

Is there evidence of Statistical Process Control for all Special Characteristics or charges as identified and established in the Control Plan?

Is there evidence that the failure methods with action are sent over to the Process Control Plan?

Are sufficient controls in position for all characteristics?

Are the top RPNs addressed with suggested actions and the actions are implemented?

Does FMEA drive Process Improvements as the primary objective, with importance on Error/Mistake Proofing solutions?

7. Control Plan

Are all sections filled out including proof of cross-functional team engagement?

Does the Control Plan provide detail processes of correcting out of control processes, handling nonconforming goods, and corrective action program on all quality problems including attribute variables?

Are gage methods cooperative and are they traceable to national standards?

Are detailed and complete Process Control Plans in place to purchase, production, inspect, test, construct, package, and ship product for each operation performed?

Are Control Plans and input criteria evaluated with manufacturing employees?

Are Engineering Test and Performance requirements recognised?

Are Special Characteristics and other major, important, characteristics of special interest, etc. process variables identified?

Is there a documented plan for producing sample sizes and test frequencies in place?

Does the Control Plan provide detail on: machine production, machine type, machine number/identification, etc.?

Are Process Control Plans completed/updated for new product or design changes?

Is there proof of feedback from customer concerns or rejections?

Are there Process Control Plans in place for all customer part numbers?

Is all production equipment distinguished (i.e. press type, paint booth type, etc.) ?

Is receiving inspection, method inspection, and final inspection contained in Control Plan?

Have all received customer concerns been classified to facilitate the selection of Special Required/Design/Process Characteristics?

Are suitable reaction plans in the Control Plan?

Are Control Plans completed and readily available for an alternate or backup process?

8. Measurement System Analysis

Do all MSAs point towards the correct part number and/or gage family?

Have correlation concerns been addressed?

Did the supplier submit an adequate MSA as above and listed in the AIAG MSA Manual?

Are MSAs concerning all (including attribute, process controls, etc.) gages documented on the control plan implemented?

Have results been examined and approved by the customer?

9. Dimensional Results

Is there proof that all specifications and other requirements were documented?

Are the correct numbers of parts laid out?

Is any nonconformance highlighted in the documentation?

Do all requirements, including drafting notes have a response (pass/fail statement is unacceptable)?

Are the dimensions recommendations on an inflated customer drawing or documented within a characteristics library?

Are all special characteristics highlighted?

Do the results comply with all design record requirements?

Is the layout result readable and understandable?

Are the inspection sheets signed and confirmed?

Do all reports comply with customer specifications?

10. Records of Material / Performance Test Results

Are material and performance test results implemented for chemical, physicals or metallurgical to the customer designation and compliance approved?

Is any non-conformance emphasized in the report?

Is product testing done internally?

Is all testing reviewed with actual criteria and data (pass/fail statement is unacceptable)?

Are all testing outcomes less than one year old?

Does the template contain the correct part and change status, specification numbers, date and change status, and authorized change documents not yet incorporated into the design? Does it also include the test date, quantity tested, actual results and the name of the material supplier? If requested by the customer, also the supplier code assigned by the customer, special requirements for the approved steel, heat treatment, coating, etc. and other relevant information specifically requested by the customer?

Is the specified test sampling size and/or frequency possible?

Is test loading adequate to provide all conditions, i.e. production validation and end-use?

Have parts produced at a minimum and maximum specification been tested?

Can additional samples be inquired when a reaction plan demands it?

11. Initial Process Studies

Were results used in determining preventative maintenance schedules?

Is the method utilized to perform investigations and rate capability level documented along with proof that results are within customer requirements?

Is there precautionary subsistence, gage and fixture calibration, tooling verifying needed to sustain an acceptable level of capability?

Is the calculation method/device noted?

Were correlation studies needed and done?

Are results for standard deviation and the administration noted?

Is variable data publishing preferred for process capacity reporting?

Was a study or test performed on the packaging of goods for shipment, assembly operations, and final product conformance?

Does the data show that the process is under control?

Is the sample size according to the agreed-upon criteria and documented within the resignation?

Are capability studies conducted on new product and/or design changes and when process variations are implemented?

Is there proof of capability results feedback to management and manufacturing staff?

Is the attribute data showing zero mistakes found?

Is a mechanism in place to feedback the product testing results to the capability study?

Is there a program to modernise the studies on a routine basis?

12. Qualified Laboratory Documentation

Does the lab scope list all tests performed by the lab?

Is the quantity tested and reported?

Has customer permission/support been obtained for the test?

Are all special characteristics from the drawing (and drawing notes) added?

Has testing specification been done on all tests?

Is a full, signed and dated lab scope accessible?

Are results documented on the letterhead?

Are performance test results and material (chemical, metallurgical, etc.) test results included?

Is any nonconformance emphasized in the report?

Are qualified independent laboratory tests defined?

13. Appearance Approval Report

Are appearance details classified on the construction drawing?

14. Sample Production Parts

Are the formal needs for samples written down?

Is there a formal, approved, controlled waiver for samples added?

Are the samples sent before PPAP submission with documentation of the components included?

Were the samples measured from taken from the Production Trail Run or a production run?

15. Master Sample

Is there proof of a standard-compliant master sample?

Are there any master samples for multiple dies, cavities, moulds, impressions, etc.?

Are master samples controlled for life of PPAP documents or until a new unit is approved and disposition of old sample?

Is there a formal, approved, controlled waiver in place for master sample or documentation to use a master sample in production?

Is the master sample established and signed by the customer and known as a master sample?

16. Checking Aids

Do all checking aids have adequate Measurement Systems Analysis studies?

Is resignation according to customer-specific demands?

Are all checking aids numbered, calibrated, added in the Control Plan and implemented for preventive maintenance plans?

Were prints, copies and duplication gages submitted?

17. Customer Specific Requirements

Does reporting take place for those demands listed and all others identified by PPAP approver representative plus other process partners (met lab, engineering, logistics, etc.)?

Is a list of “Specific Requirements” along with compliance documentation in place or a renounce that doesn't exist?

18. Part Submission Warrant

Is the warrant compliant recording to the AIAG PPAP standard?

Is decent detail given for “Reason for Submission”?

Are all areas finished as per PPAP instructions?

Is a completed bulk material checklist and a license in place for all bulk material utilised in production parts? (See page 36 of AIAG PPAP 4th edition Manual)

Give the submission level

Are specific elements clearly recognised for the submission?

Are all 16 elements provided along with a full description of any that are not provided in full?

Completion

Write down some additional comments:

Quality Manager Name & Signature

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This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.