# PPAP Elements, Levels and Triggers (AIAG PPAP 4th edition)

## The 18 elements

| # | Element | Content |
|---|---------|---------|
| 1 | Design records | Customer drawing / CAD with every characteristic ballooned; supplier design records if design-responsible |
| 2 | Authorized engineering change documents | Changes not yet on the drawing (ECN, deviation) |
| 3 | Customer engineering approval | Engineering approval when the customer requires it (e.g. validation tests) |
| 4 | Design FMEA | If the supplier is design-responsible |
| 5 | Process flow diagram | Every step from receiving to shipping, incl. rework and inspection |
| 6 | Process FMEA | Linked to the flow diagram, AIAG-VDA method or as the customer requires |
| 7 | Control plan | Production control plan matching PFMEA and flow |
| 8 | MSA studies | Gage R&R, bias, linearity, stability for new or modified gauges; attribute agreement |
| 9 | Dimensional results | Every drawing characteristic measured on the sample parts (often 5 parts per cavity / process stream) |
| 10 | Material and performance test results | Chemical, physical, metallurgical and functional tests per drawing and specifications |
| 11 | Initial process studies | Ppk (or Cpk) for special characteristics, >= 100 readings, 25+ subgroups |
| 12 | Qualified laboratory documentation | Lab scope and accreditation (ISO/IEC 17025 for external labs) |
| 13 | Appearance approval report | For parts with appearance requirements (colour, grain, gloss) |
| 14 | Sample production parts | From the significant production run |
| 15 | Master sample | Retained, signed sample for training and reference |
| 16 | Checking aids | Fixtures and gauges specific to the part, with MSA and calibration |
| 17 | Customer-specific requirements | Records for each applicable CSR |
| 18 | Part submission warrant | Summary declaration signed by an authorized person |

## Requirements by level (S submit, R retain, * customer defines)

| # | Element | L1 | L2 | L3 | L4 | L5 |
|---|---------|----|----|----|----|----|
| 1 | Design records | R | S | S | * | R |
| 2 | Engineering change documents | R | S | S | * | R |
| 3 | Customer engineering approval | R | R | S | * | R |
| 4 | Design FMEA | R | R | S | * | R |
| 5 | Process flow diagram | R | R | S | * | R |
| 6 | Process FMEA | R | R | S | * | R |
| 7 | Control plan | R | R | S | * | R |
| 8 | MSA studies | R | R | S | * | R |
| 9 | Dimensional results | R | S | S | * | R |
| 10 | Material / performance results | R | S | S | * | R |
| 11 | Initial process studies | R | R | S | * | R |
| 12 | Qualified laboratory documentation | R | S | S | * | R |
| 13 | Appearance approval report | S | S | S | * | R |
| 14 | Sample production parts | R | S | S | * | R |
| 15 | Master sample | R | R | R | * | R |
| 16 | Checking aids | R | R | R | * | R |
| 17 | Customer-specific requirements | R | R | S | * | R |
| 18 | PSW | S | S | S | S | R |

Level 3 is the default unless the customer specifies otherwise. Retained items must be available on request
and kept for the part's active life plus one year (IATF 7.5.3.2.1).

## When a PPAP is required

New part or product; correction of a discrepancy on a previous submission; product modified by an engineering
change; change of material or construction; tooling transfer, replacement or refurbishment; new or rearranged
equipment; change to manufacturing process or method; change of sub-supplier or material source; production
from tooling inactive for 12 months or more; change of test or inspection method; change of manufacturing site.
Notify the customer **before** the change; the customer may waive submission, but records are still updated.