PPAP (Production Part Approval Process): 5 Levels Explained
Which documents each level of the Production Part Approval Process requires, from Level 1 to Level 5, and why automotive typically uses Level 3.
The 5 levels of PPAP
- 1
Part Submission Warrant only (no sample)
Only the signed PSW (Part Submission Warrant) form is sent, with no physical samples or additional documentation. Used when the customer has high confidence in the supplier or for very low-risk parts.
- 2
PSW with samples and limited supporting data
The PSW is sent together with product samples and limited supporting data (for example, basic dimensional results), without the full documentation package.
- 3
PSW with samples and complete documentation package
This is the most common level in the automotive sector. It includes the PSW, product samples and the complete evidence package: design record, design and process FMEA, process flow diagram, control plan, capability studies (Cpk), full dimensional report, material and performance test results, and lab certification.
- 4
PSW and other customer-defined requirements
The customer specifies exactly which documents are required, which may be a custom combination different from the standard levels. This is less common and is used when the customer has specific requirements not covered by levels 1-3.
- 5
PSW with on-site review at the supplier’s facility (no submission)
The customer reviews all documentation and samples directly at the supplier’s facility, with nothing physically shipped. Reserved for safety-critical parts or new high-risk suppliers where the customer wants full on-site verification.
Typical documents in the complete PPAP package (Level 3)
| Document | What it demonstrates |
|---|---|
| Design record (drawing) | Dimensional specifications and tolerances of the part |
| DFMEA / PFMEA | Analysis of design and process failure modes |
| Process flow diagram | Complete sequence of manufacturing operations |
| Control plan | Control points, method and inspection frequency |
| Capability study (Cpk) | Process capability to meet tolerances (typical minimum 1.33) |
| Dimensional report | Actual measurement of each critical part dimension |
| Material test results | Chemical and mechanical conformity of the material used |
| PSW | Formal declaration of conformity signed by supplier quality |
Frequently asked questions — PPAP
Which PPAP level does the automotive industry typically use?
Level 3 is the default standard in most automotive programs, unless the customer specifies a different level in their Customer Specific Requirement. It includes the full documentation package: FMEA, control plan, Cpk, dimensional report and material certificates.
What is the PSW form and what does it contain?
The PSW (Part Submission Warrant) is the summary document certifying that the supplier has completed the PPAP process and that the part meets all customer requirements. It includes part data, the reason for submission (new part, engineering change, supplier change), evaluation results, and the declaration of conformity signed by the supplier’s quality manager.
When must a new PPAP be submitted?
A new PPAP is required for: a new or modified part, a design engineering change, a change of raw material or subcomponent supplier, a change to the manufacturing process or plant location, a significant tooling change, or after a prolonged production shutdown (typically more than 12 months) per the customer’s requirement.
What is Cpk and why is it mandatory in PPAP level 3?
Cpk (process capability index) measures whether the manufacturing process is capable of consistently producing within specified tolerances. The automotive standard typically requires a minimum Cpk of 1.33 for special characteristics, demonstrated with at least 30 consecutive process measurements under normal production conditions.
Who approves or rejects a PPAP?
The customer’s quality team (usually OEM supplier quality engineering) reviews the submitted documentation and decides: Approved (the supplier can produce in series), Interim approval (temporary authorization while pending evidence is completed, with a defined deadline), or Rejected (the supplier must correct and resubmit).
What happens if the PPAP is rejected?
The supplier must identify the causes of the rejection (incomplete documentation, out-of-spec results, insufficient Cpk), fix the problem and resubmit the full package. Series production cannot start until approval is obtained, unless the customer explicitly grants an interim approval with an action plan.
Can IgeraIndustria help prepare the PPAP package?
IgeraIndustria indexes your historical FMEAs, control plans and dimensional reports, allowing your quality team to quickly locate existing documentation and verify that the PPAP package is complete before submission, citing the exact source of each document.
Locate your PPAP documentation instantly
IgeraIndustria indexes FMEAs, control plans and dimensional reports so your team can verify the complete PPAP package before sending it to the customer.
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