Free template
PPAP checklist
PPAP, the production part approval process, is how an automotive supplier shows its customer that it understands every requirement for a part and that its production process can make it to those requirements at the quoted rate. It is defined in the AIAG PPAP manual, which lists 18 elements, from the design records to the part submission warrant (PSW), and five submission levels that set what is sent to the customer and what is kept on file. This checklist lists the 18 elements with columns for whether your customer needs each one for this submission, submit or retain, owner, due date, status and document reference. It also has the submission level, the reason for submission, a readiness count, open issues, the production run the parts came from, the warrant and the customer's disposition. The Excel version flags elements that are late, have no owner or no due date, and works out the percentage ready and the days left to the submission date.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use a PPAP checklist
- For a new part, before the first production shipment to the customer.
- For an engineering change, new or moved tooling, a new material or supplier, or a process or site change, where your customer requires a new submission.
- To plan the PPAP as a project, with an owner and a date for each element.
- To check a supplier's submission to you against the same list.
How to fill it in
- 1
Agree the level and the elements
Level 3 is the default unless the customer asks for another. Confirm which elements they want submitted, which are kept on file, and any customer-specific requirements.
- 2
Give each element an owner and a date
Design records and change documents from engineering, the flow, PFMEA and control plan from the process team, MSA and dimensional results from quality, and so on.
- 3
Run production parts
The parts for the submission come from a significant production run, on production tooling, gauges, process and people, at the production rate.
- 4
Measure and test
Dimensional results for every characteristic on the design record, material and performance tests, initial process studies for the special characteristics and MSA on the gauges.
- 5
Close the open issues
Anything that stops a full approval, such as a capability below target or a missing record, goes on the open issues list with an action.
- 6
Sign the warrant and submit
Complete and sign the PSW, send what the level asks for, and record the customer's disposition: approved, interim approval or rejected.
What's on the checklist
The 18 elements on the PPAP checklist
Numbered as in the AIAG PPAP manual. On the sheet each element has columns for whether your customer needs it, submit or retain, owner, due date, status and the document reference.
The 18 PPAP elements
Numbered as in the AIAG PPAP manual
- 1Design records: the released drawing and specifications
- 2Authorized engineering change documents, for changes not yet on the drawing
- 3Customer engineering approval, where the customer requires it
- 4Design FMEA, if you are responsible for the design
- 5Process flow diagram covering every step from receiving to shipping
- 6Process FMEA covering every step in the process flow
- 7Control plan for the production process
- 8Measurement system analysis (MSA) studies, such as gauge R&R, for the gauges in the control plan
- 9Dimensional results for every characteristic on the design record
- 10Records of material and performance test results
- 11Initial process studies: capability of the special characteristics
- 12Qualified laboratory documentation for the labs that did the tests
- 13Appearance approval report (AAR), if the part has appearance requirements
- 14Sample production parts from the production run
- 15Master sample, kept for reference
- 16Checking aids: fixtures and gauges made for this part
- 17Records of compliance with customer-specific requirements
- 18Part submission warrant (PSW), completed and signed
A filled-in example
Illustrative, not a benchmarkAn example: tracking a level 3 submission for a new stamped bracket (illustrative).
- Customer needs 16 of the 18 elements: no design FMEA (the customer owns the design) and no appearance approval report.
- Three weeks before the due date: 9 done, 5 in progress, 2 not started; the checking fixture was late from the toolmaker.
- Open issue: one hole position had a capability below the customer's target in the initial study.
- Action: the die was adjusted and the study repeated on a new run before the warrant was signed.
All 16 elements were done two days before the due date and the customer gave full approval. Without the checklist, the late fixture would have been found in the last week.
Common mistakes
Parts from a trial run
PPAP parts must come from a significant production run on production tooling and process, not hand-picked parts from a prototype run.
Not agreeing the level first
Assuming level 3 when the customer wants something else, or missing a customer-specific requirement, means a rejected submission.
Documents that disagree
The process flow, PFMEA and control plan must list the same steps. Reviewers look for the mismatch.
Starting in the last month
Gauges, fixtures, lab tests and capability studies take time. Plan the PPAP from the tooling kick-off.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
LeanSuite runs part-specific receiving inspections on a tablet with required photos, routes each defect as a SCAR to Quality and Procurement, and builds a supplier scorecard with defect PPM by vendor.
In the lean glossary
FAQ
PPAP checklist: common questions
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