PPAP requirements checklist

This checklist is customizable for all PPAP levels (1-5). First determine your customer’s required submission level, then use this checklist to verify the corresponding elements. Level 1 requires only the warrant, while Level 5 requires complete documentation. The checklist helps ensure you’ve addressed all required elements for your specific submission level.

eview your FMEA with a cross-functional team to identify all potential failure modes. Focus on those with high severity ratings (8-10) and ensure they have adequate detection and prevention controls. Use historical data, field reports, and warranty claims to validate your risk assessments. The checklist confirms you’ve completed this critical evaluation.

Include Gage R&R studies showing acceptable variation percentages (typically under 30%), calibration certificates for measuring equipment, and MSA studies for attribute gages. The checklist confirms you’ve evaluated measurement system capability before relying on these systems for production decisions.

Use this checklist during internal reviews before customer submission. Track which items consistently fail verification to identify systemic weaknesses in your PPAP process. Create training and process improvements targeting these weak areas. The checklist becomes a continuous improvement tool when used consistently across projects.