What is PPAP?
Many industrial companies require that their parts providers utilize PPAP processes. PPAP, or the Production Part Approval Process, is used by almost every industry that produces and services part commodities. It is the standard utilized to ensure quality and efficiency with regard to part production.
PPAP is an effective way to monitor financial prudence as well; its effective audits include the measurement of performance, the analysis of the return on investment in any given parts production process and the business case analysis for the production process. Legal prudence and industry standard conformance are also measured.
PPAP is a set of standards within a larger set of standards called APQP, which stands for Advanced Product Quality Planning. This umbrella term is used for formalized standard and defined step-by-step processes to providing quality parts for the end customer.
History
In 1982 the management staff of General Motors, Chrysler and Ford Motors founded AIAG (Auto Industry Action Group). The group then created to Advanced Product Quality Planning & Control Plan (APQP), within these standards, the AIAG developed PPAP to advance the parts production approval process of quality planning.
Industries
Primarily, the automotive and semiconductor industries utilize PPAP standards and processes. However, any industry that implements ISO/TS 16949 also uses PPAP standards. ISO/TS 16949 are connected to the application of ISO 9000 standard sets, which are required for the legal international distribution of various parts.
Purpose
Ultimately the PPAP being utilized is required so that the customer can expect a zero-defects part. This is accomplished by production tooling analysis prior to actual mass part production. By using the PPAP, process testing reports are generated with every product, and the customer is ensured that their are expectations met every time, even though massive orders, constant transactions and global exchange complicate the parts business.
Process
During the phase of production for quality planning, a process flow chart is created. From this chart, a Process Failure Mode and Effects Analysis (PFMEA) is established. A control plan is then drawn up based upon the results of the PFMEA.
The control plan is developed detailing how the processes are controlled and how any issues with noncompliance are handled. (Manufacturing process audits require control plans as a main portion of the documentation requirements.) A Gauge R&R, or Gauge Repeatability and Reproducibility Analysis, is then necessary.
Next, a sample manufacturing utilizing the specified production run is required to prove out the processes. The results of this sampling production run are then analyzed and documented statistically to complete the PPAP.
Training
PPAP training is offered by itself or as part of the training provided within the APQP training courses. These training courses can be found on the AIAG website. The PPAP course costs $200.00, and the APQP course costs $995.00. Both are accredited. These courses teach documentation, parts production and quality control processes and requirements.
Tags: parts production, PPAP standards, Advanced Product, Advanced Product Quality, control plan, course costs