Production Part Approval Process - PPAP Approval

PPAP Approval

The result of this process is a series of documents gathered in one specific location (a binder or electronically) called the "PPAP Package". The PPAP package is a series of documents which need a formal approval by the supplier and customer. The form that summarizes this package is called PSW (part submission warrant). The approval of the PSW indicates that the supplier responsible person (usually the Quality Engineer) has reviewed this package and that the customer has not identified any issues that would prevent its approbation.

The documentation on the PPAP package is closely related to the advanced product quality planning process used during the design and development of new vehicles and component systems to reduce the risk of unexpected failure due to errors in design and manufacture. The PPAP manual is published by the AIAG, and specifies generic requirements for obtaining PPAP approvals. Additional customer specific requirements may be imposed by particular clients (vehicle manufacturers) and incorporated in the purchasing contracts. Details of 'customer specific' requirements may be found on the International Automotive Task Force (IATF) website or supplier portals provided by the vehicle manufacturers. A new website, developed by customer-specific requirements, LLC, has been created to help solve problems associated with the distribution and accessibility of customer-specific requirements.

Suppliers are required to obtain PPAP approval from the vehicle manufacturers whenever a new or modified component is introduced to production, or the manufacturing process is changed. Obtaining approval requires the supplier to provide sample parts and documentary evidence showing that:

1) The clients requirements have been understood
2) The product supplied meets those requirements
3) The process (including sub suppliers) is capable of producing conforming product
4) The production control plan and quality management system will prevent non-conforming product reaching the client or compromising the safety and reliability of finished vehicles

PPAP may be required for all components and materials incorporated in the finished product, and may also be required if components are processed by external sub-contractors.

The term ISIR (initial sample inspection report) is being used by Germany companies like VW and BMW. ISIR form is standardized by Verband der Automobilindustrie e. V., short VDA, a German interest group of the German automobile industry, both automobile manufacturers and automobile component suppliers. The term is also used by some other companies like Hyundai and Kia. In fact ISIR is like the Warrant and Inspection Report of PPAP document package. PPAP document package includes some other document such as PFMEA, control plan, drawing, MSA, capability data etc. Besides ISIR document, other documents like that of PPAP is normally required by VW and Hyundai for release of a product and process. The PPAP is like the older ISIR plus a lot more, unless your customer has a specific requirement for using their ISIR within their system. ISIR is a summary of the initial sample being presented at what ever state. The PSW is supported and validated by the ISIR. This does not mean the product being presented is under serial conditions but just states with evidence the current status.

PPAP is the confirmation that the product meets the customer requirements for series production. The PPAP will be considered signed when a full PSW is approved by your customer and added to the PPAP folder. The PSW would always be supported with a ISIR but the PPAP is only considered approved when a FULL PSW is endorsed with an ISIR.

In essence the PSW and ISIR are part of PPAP or VDA and can even be outside of PPAP in cases such as first off tool parts which should be submitted in most cases with a PSW and ISIR but will not be approved in PPAP until series conditions are met.

The ISIR is the part of the PPAP which includes the product ballooned drawing, layout and the capability study (Cpk's). It may sometimes be separately requested by the customer annually or in the event of repeating nonconformance.