The customer wants proof that you can make the same good part every day.
This is where PPAP – Production Part Approval Process is used.
PPAP is not a form.
PPAP is a promise with evidence.
What Problem PPAP Solves
Many suppliers face these issues:
Sample is OK, but mass production fails
Quality drops after few weeks
Customer rejects parts after dispatch
PPAP is used to stop these problems before they start.
It proves that:
Design is understood
Risks are already studied
Process is under control
Quality is repeatable
PPAP in Simple Words
PPAP means showing the customer:
“This part is correct.
This process is stable.
We can supply this quality continuously.”
Only after PPAP approval, mass production is allowed.
How PPAP Works in Real Life
Before PPAP approval, the supplier must show:
Part is made as per drawing
Process flow is clearly defined
Possible failures are identified in advance
Measuring instruments are accurate
Trial production results are consistent
This gives confidence to the customer and discipline to the supplier.
Why PPAP Has 18 Elements
Each PPAP element answers one important question:
Is the design correct?
What can go wrong in design or process?
How are risks controlled?
Are measurements reliable?
Is the process capable?
Together, these elements show that quality is planned, not inspected.
PPAP Levels – Not All Customers Ask the Same
Some customers want only documents.
Some want samples.
Some want full documents and factory audit.
That is why PPAP has 5 submission levels, from basic to detailed.
Most automotive customers ask for Level 3 PPAP.
Example from Shop Floor
If a supplier is making brake pads:
One bad pad can cause an accident
Customer will not take risk
PPAP ensures:
Material strength is tested
Process variation is controlled
Every brake pad meets safety standards
Common Mistake Suppliers Make
Many suppliers think:
“PPAP is customer pressure.”
Reality is:
“PPAP protects the supplier also.”
A good PPAP:
Reduces rework
Reduces customer complaints
Improves internal process discipline
Final Thought
Inspection finds problems.
PPAP prevents problems.
Companies that respect PPAP:
Grow faster
Build long-term customers
Win repeat business
Follow me on LinkedIn for practical production and operations knowledge.
Written by: Pandhrinath Ratnparakhe
If you want:
