A PPAP proves that production tooling, processes and people make parts that meet every requirement at the quoted
rate. Rejections usually come from missing elements for the level, a PSW signed despite a known nonconformity,
or initial process studies that do not meet the acceptance index. scripts/ppap_package.py lists and checks the
elements; scripts/psw_check.py checks the warrant and study results before anyone signs.
Trigger Conditions
Activate this skill when the user:
- Is preparing a PPAP for a new part or a change (material, tooling, process, site, sub-supplier)
- Asks what to submit for level 2, 3 or another level
- Is filling in a PSW or reviewing initial process study results
- Had a PPAP rejected or received interim approval
Upstream deliverables: apqp-phase-planner, process-fmea-builder, control-plan-writer, gage-rr-msa-analyzer, manufacturing-cpk-capability-calculator.
Workflow
1. TRIGGER -> confirm a PPAP is required (new part or change) and notify the customer before the change
2. LEVEL -> level from the customer (default 3); appearance item? design responsibility?
3. ELEMENTS -> python scripts/ppap_package.py --level 3 --have have.txt [--no-appearance] [--no-design]
4. RUN -> significant production run with production tooling, people and rate; take samples
5. STUDIES -> MSA, dimensional results on every characteristic, Ppk on special characteristics
6. PSW -> python scripts/psw_check.py psw.json (no high findings before signing)
7. SUBMIT -> package per level; track approval status (approved / interim / rejected)Submit vs Retain (level 3, the default)
All elements are submitted except master sample and checking aids (retained). Level 1 submits only the PSW (and appearance approval report); level 2 adds design records, changes, dimensional and material results, lab documentation and samples; level 4 is as the customer defines; level 5 is reviewed on site. Full table, element content and PPAP triggers: ppap-elements.md.
PSW Checks (psw_check.py)
| Code | Severity | Problem |
|---|---|---|
| PS001 | high | Identification incomplete |
| PS002 | high | Weight missing |
| PS003 | high | A results declaration is not "meets requirements" |
| PS004 | high / medium | Special (high) or other (medium) characteristic index < 1.33 |
| PS005 | medium | Index 1.33-1.67, or unstable process: customer approval needed |
| PS006 | medium | Fewer than 100 readings |
| PS007 | medium | Reason or level missing |
| PS008 | medium | Material reporting (IMDS) missing |
| PS009 | low | Not signed / dated |
PS005 [medium] Flange thickness 8.0 +/-0.1: index 1.41 between 1.33 and 1.67 - contact the customer for approvalPSW fields, acceptance criteria, approval statuses and dimensional results rules: psw-and-acceptance.md.
Output Format
Deliver:
- Submission summary - part, reason, level, customer.
- Element table - submit / retain / n/a and status (from
ppap_package.py). - Study results - special characteristics with index and n, and the acceptance decision.
- PSW check - findings and the sign / do-not-sign recommendation.
- Open actions - missing elements and items needing customer agreement, with owners.
Scripts
python scripts/ppap_package.py --level 3
python scripts/ppap_package.py --level 3 --have have.txt --no-appearancehave.txt lists prepared elements by number, name or abbreviation (PSW, AAR, DFMEA, PFMEA, MSA). Exit codes:
0 complete or listing only, 1 elements to submit are missing, 2 read error.
python scripts/psw_check.py psw.jsonExit codes: 0 no high findings, 1 high findings (do not sign), 2 read or JSON error.
Additional Resources
| File | Content |
|---|---|
| ppap-elements.md | The 18 elements, submit/retain table for levels 1-5, PPAP triggers |
| psw-and-acceptance.md | PSW fields, initial process study acceptance, approval statuses, dimensional results |
8d-problem-solving-report-writer
Write and review 8D problem-solving reports for customer complaints and serious nonconformities (automotive and aerospace practice: Ford Global 8D, VDA, GM, Stellantis formats): D0 emergency response, D1 cross-functional team and champion, D2 problem description with 5W2H and is / is-not and no cause in the statement, D3 interim containment within 24 hours with verification and clean point, D4 verified occurrence and escape (non-detection) root causes plus systemic cause, D5 permanent corrective actions for each cause verified before implementation, D6 implementation, validation with production data and removal of containment, D7 PFMEA, control plan and read-across to similar products, D8 closure and recognition. Checks an 8D discipline by discipline for missing content, human-error root causes, missing escape cause or action, late containment and dates out of order.
acceptance-sampling-plan-selector
Select and evaluate acceptance sampling plans for incoming, in-process and final inspection: ANSI/ASQ Z1.4 / ISO 2859-1 single sampling under normal inspection (code letter from lot size and inspection level I, II, III, S-1 to S-4; sample size, Ac and Re from AQL, following the table's arrows to the correct plan; 100% when n reaches the lot size; AQLs above 10 per 100 units), operating characteristic curves (Pa at any quality, producer's quality level, indifference point, LTPD, AOQ and AOQL, binomial or hypergeometric), plans designed from producer and consumer risk, and c = 0 zero-acceptance plans. Covers AQL choice by defect class, switching rules between normal, tightened and reduced inspection, when sampling is not appropriate, and random sampling.
approved-supplier-list-manager
Manage and audit an approved supplier list (ASL) / external provider register for ISO 9001 8.4.1, IATF 16949 8.4 and AS9100 8.4.1: supplier status (approved, conditional, probation, pending, disqualified), scope of approval by commodity and process, risk class, certification and expiry, re-evaluation intervals by risk, conditions with end dates, single-source contingency, approver and customer-directed sources. Audits the list for expired or expiring certificates, overdue re-evaluations, conditional or probation status past its decision date, high-risk suppliers without the required certification, single-source suppliers without backup and missing approvers, and checks purchase orders for suppliers that are off-list, disqualified or pending, or buying outside the approved scope. Covers ERP blocks, PO requirements, off-list and emergency purchases.
apqp-phase-planner
Plan and track Advanced Product Quality Planning (AIAG APQP 3rd edition, IATF 16949) for a new or changed automotive part: back-schedule the five phases (plan and define, product design, process design, product and process validation, launch and feedback) from the start-of-production date by program complexity, with overlap, PPAP lead and safe-launch period; list the deliverables and gate for each phase (DFMEA, DVP&R, feasibility, process flow, PFMEA, control plans, MSA, Ppk, run at rate, PPAP, safe launch, lessons learned); adjust for build-to-print suppliers; flag compressed timelines and late or untracked deliverables against a status list. Covers gate reviews, red/yellow/green status reporting, run at rate and safe-launch exit criteria.
as9100-gap-analyzer
Run an AS9100D / EN 9100:2018 gap analysis for aviation, space and defence suppliers on the requirements added to ISO 9001: on-time delivery and conformity focus, management representative, ethics and human-factors awareness, operational planning and operational risk management, configuration management, product safety, counterfeit-part prevention, special requirements, critical items and key characteristics, external provider register and flow-down, FOD prevention, tooling and NC program control, special process validation, first article inspection (AS9102), traceability, in-service data and nonconforming product control. Generates and scores a worksheet, grades missing core controls as major, and checks invalid n/a claims. Covers AS9101/AS9104, OASIS, AS9102 FAI forms, counterfeit standards (AS5553, AS6174, AS6081), NADCAP and the planned IA9100 transition.
audit-report-writer
Write internal, supplier and pre-certification audit reports with the content ISO 19011:2018 6.5 expects: audit objectives, scope, criteria with revisions, dates, team and auditees, method and sampling statement, specific strengths, findings table and three-part finding details (requirement, evidence, statement), conclusion on the degree of fulfilment of criteria, diverging opinions, follow-up deadlines and distribution. Builds a Markdown report from a JSON audit record, generates the conclusion from the findings (major / minor / none) and flags reports missing required content or findings without clause or evidence. Covers conclusion wording, closing meetings, response expectations and verifying corrective actions.