What is PPAP?
PPAP is a standardized process in the automotive industry (outlined in the AIAG manual, now merged into IATF 16949) used to validate that a supplier’s production process can consistently manufacture a part that meets all customer specifications and requirements. It’s proof that the supplier understands the part and can mass-produce it without fail.
Core Importance for a New Project
- For the Customer (OEM or Tier-1)
- Risk Mitigation: PPAP is the primary gate that prevents flawed parts from entering the customer’s assembly line. It verifies the process before full-scale production begins, avoiding costly line stoppages, recalls, or warranty claims.
- Assurance of Capability: It provides documented evidence (not just promises) that the supplier’s process is capable (Statistical Process Control – SPC) and that the parts produced meet all design and functional requirements.
- Standardization: It creates a common language and expectation between customer and supplier worldwide. Every party knows what “approval” entails.
- Legal & Contractual Clarity: The PPAP submission is a formal record of what was approved. It protects both parties if disputes arise later about part conformity.
- For the Supplier (Manufacturer)
- Process Validation and Discipline: The PPAP process forces the project team to rigorously document and validate every aspect of production early. This often uncovers hidden issues (e.g., a gauge not being capable, a fixture causing variation) that can be fixed before expensive tooling is committed or production runs.
- Avoids Costly Late Changes: By requiring full validation of design records, materials, and processes, PPAP ensures that the supplier is building the part exactly as the customer intended. This prevents the catastrophic cost of discovering a mismatch after thousands of parts are made.
- Foundation for Production: A successful PPAP means the process is stable, capable, and ready for ramp-up. It builds confidence in the production team and provides the essential documentation (Control Plan, Flow Chart, SPC data) needed for long-term quality control.
- Winning and Keeping Business: A robust and timely PPAP submission is a key indicator of a supplier’s competence and professionalism. It’s often a contractual requirement; failure to submit or gain approval can result in loss of business or financial penalties.
Consequences of NOT Performing PPAP or Doing It Poorly
- Production Part Delays: PPAP rejection stops the project clock, delaying revenue and potentially incurring late penalties.
- Massive Scrap/Rework Costs: Producing parts with an unapproved process can lead to entire batches being non-conforming.
- Line Stoppages at Customer: The most severe outcome—your defective part shuts down their assembly line, leading to enormous financial claims and loss of trust.
- Damage to Supplier Reputation: A poor PPAP record marks a supplier as unreliable, jeopardizing future business.
In short, a successful PPAP is the definitive sign-off that the development phase is complete and the project is ready for a stable, high-quality launch into mass production. It is an investment in prevention that saves enormous costs in correction.
