PPAP — Production Part Approval Process

PPAP is the automotive industry's method for approving new or changed production parts before mass production. A PPAP package contains up to 18 elements that prove the production process can consistently produce parts that meet all design and specification requirements.

Why companies use it

·OEM customers require PPAP submission before approving any new or changed supplier part
·Provides evidence that the manufacturing process is stable, capable, and controlled
·Protects both supplier and customer by documenting mutual agreement on product and process requirements
·Reduces supply chain risk by establishing a quality baseline before volume production starts

What hiring managers look for

·PPAP experience signals that a candidate has navigated real production launches, not just prototype builds
·Knowing which elements apply at each submission level (1–5) shows practical experience
·The ability to compile a complete PPAP package quickly under customer pressure is a valued skill
·Understanding PSW (Part Submission Warrant) sign-off process shows cross-functional coordination skills

Typical interview questions

What are the five levels of PPAP submission and when would you use each?

Which PPAP elements are always required regardless of submission level?

How do you handle a situation where a customer requests a Level 3 PPAP but your Cpk results are below 1.67?

What is the difference between interim approval and full PPAP approval?

Describe how you have compiled a PPAP package. What was the most challenging element to complete?

Common mistakes

·Submitting PPAP with a Cpk below 1.67 without communicating a corrective action plan to the customer
·Forgetting that any design or process change after PPAP approval requires re-submission
·Not retaining PPAP records for the required retention period (typically part life + one year)
·Treating the Dimensional Results as a formality — sampling must represent actual production conditions
·Missing the Material Safety Data Sheet (MSDS) / IMDS submission for regulated substances

Real engineering example

A Dutch precision machining supplier was rejected on their first PPAP submission for a semiconductor equipment bracket. The customer rejected the dimensional results because measurements were taken on freshly machined parts before stress relief, not on production-representative samples from the actual production tooling. After proper process stabilisation and re-measurement, Cpk improved from 1.12 to 1.82 and full approval was granted.

Topics covered

PPAPautomotiveCpkPSWAIAGproduction approvalquality