Free training deck
Updated · About 45 minutes
PPAP and APQP training presentation
APQP (advanced product quality planning) is the automotive method for planning a new part and its process in five gated phases. PPAP (production part approval process) is the evidence package the supplier sends to prove the plan worked. This free deck teaches both in about 45 minutes. Its 19 editable slides cover the five APQP phases, APQP against PPAP, the core tools that sit inside a launch, gate reviews, the control plan, the 18 PPAP elements, the five submission levels, the significant production run and capability criteria, when a new PPAP is needed, an illustrative launch that slips, the common mistakes, a 15-minute gap walk and four check questions with answers. Every slide has speaker notes.
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The title PPAP and APQP, planning a launch and proving it, on a navy background with the LeanSuite logo.A look inside
What is in the 19 slides
For quality engineers, launch teams, process engineers, supplier quality staff. Widescreen, in plain language, with speaker notes on every slide.
Slide 4: The five phases of APQP 
Slide 14: Example: a launch that slips at the gate 
Slide 16: Try it: a PPAP gap walk
- 1PPAP and APQP: planning a launch and proving itCover
- 2AgendaAPQP and PPAP: what each is for · The five phases, the gates and the core tools · The 18 PPAP elements and the submission levels · The production run, capability and approval · Example, mistakes, activity and check questions
- 3What APQP and PPAP areAPQP is the plan for the whole launch. PPAP is the proof that the plan worked.
- 4The five phases of APQPPlan and define, Product design, Process design, Validation, Feedback
- 5APQP against PPAPPPAP is one deliverable inside APQP.
- 6The core tools inside a launchFMEA, Control plan, MSA, SPC, PPAP
- 7Gate reviewsA gate is a short review at the end of a phase. The team shows evidence, not slides.
- 8The control planThe control plan is the document APQP leaves on the shop floor.
- 9The 18 PPAP elements: 1 to 9The element names from the AIAG PPAP manual. The customer decides which are submitted.
- 10The 18 PPAP elements: 10 to 18Evidence and approval.
- 11The five submission levelsThe level changes what is sent. The full records stay at the plant at every level.
- 12The production run and capabilityThe parts come from a significant production run: by default one to eight hours of production, at least 300 consecutive parts.
- 13When PPAP is needed, and the outcomesA new part, or a new submission after an engineering change.
- 14Example: a launch that slips at the gateAn illustrative example: a bracket for a new program. The numbers are made up.
- 15Common mistakesCollecting customer-specific requirements late, or never.
- 16Try it: a PPAP gap walkA 15-minute team activity
- 17Check your understanding4 check questions
- 18AnswersThe answers, to discuss
- 19Key points and next stepsNext: run the gap walk on one part in your own area.
The 45-minute session, slide by slide
- Slides, about: 30 minutes
- Activity (slide 16): 15 minutes
Present · 15 slides
- 1PPAP and APQP: planning a launch and proving it
- 2Agenda
- 3What APQP and PPAP are
- 4The five phases of APQP
- 5APQP against PPAP
- 6The core tools inside a launch
- 7Gate reviews
- 8The control plan
- 9The 18 PPAP elements: 1 to 9
- 10The 18 PPAP elements: 10 to 18
- 11The five submission levels
- 12The production run and capability
- 13When PPAP is needed, and the outcomes
- 14Example: a launch that slips at the gate
- 15Common mistakes
Do the activity · 1 slide
- 16Try it: a PPAP gap walk
Check and follow up · 3 slides
- 17Check your understanding
- 18Answers
- 19Key points and next steps
About 30 minutes of slides and 15 minutes of activity. Present: slides 1 to 15 (PPAP and APQP: planning a launch and proving it; Agenda; What APQP and PPAP are; The five phases of APQP; APQP against PPAP; The core tools inside a launch; Gate reviews; The control plan; The 18 PPAP elements: 1 to 9; The 18 PPAP elements: 10 to 18; The five submission levels; The production run and capability; When PPAP is needed, and the outcomes; Example: a launch that slips at the gate; Common mistakes). Do the activity: slide 16 (Try it: a PPAP gap walk). Check and follow up: slides 17 to 19 (Check your understanding; Answers; Key points and next steps).
How to run it
Running the session
- 1
Prepare
Read the speaker notes once and swap the illustrative example for one from your own area if you have it. Print the PDF if people like a handout.
- 2
Present
The slides take about 30 minutes. Every slide has notes, so you can talk from them rather than read the slide.
- 3
Do the activity
Pick one part you make, or are about to launch, and ask which submission level the customer requires. The activity slide takes the team through it step by step; allow 15 minutes.
- 4
Check and follow up
Ask the check questions before showing the answers, then agree one next step with an owner and a date before people leave.
The check questions
- 1. What is the difference between APQP and PPAP?
- APQP is the plan for the whole launch, in five phases. PPAP is the approval package, submitted near the end of phase 4, that proves the plan worked on real production parts.
- 2. What is a significant production run by default?
- One to eight hours of production on production tooling, gauges, process, material and people, with at least 300 consecutive parts.
- 3. Which PPAP submission level is the default if the customer does not say?
- Level 3: the warrant with sample parts and the complete supporting data.
- 4. Why does the gage R&R matter to the capability study?
- The Ppk figure comes from the gauge readings. If the measurement system is noisy, the capability number cannot be trusted.
Templates and guides to go with it
- PPAP checklistThe 18 PPAP elements with owner, due date and status, the five submission levels and a readiness count.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Control plan templateWhat is checked at each step, against which limits, how, how often, and what to do when a result is out.
- PFMEA template (process FMEA)Failure modes, effects and causes rated for severity, occurrence and detection, with RPN before and after action.
- Topic: Quality managementEvery guide we have on the subject, sorted.
Read more
FAQ
PPAP and APQP training presentation: common questions
APQP is the plan for the whole launch of a new part, in five phases with a gate review at the end of each. PPAP is the approval package the supplier submits near the end of phase 4 to show the customer the process makes good parts at the quoted rate.
About 45 minutes: roughly 30 minutes of slides, a 15-minute gap walk and the check questions.
The AIAG APQP and Control Plan manual and the AIAG PPAP manual, fourth edition (2006), as publicly described. AIAG has revised some manuals since, so ask which edition your customer works to. The customer's requirements take priority.
No. It teaches the method. Each customer has its own supplier manual with its own submission level, forms and acceptance values, and those override the defaults shown here.
Yes. The PowerPoint file is fully editable, including the speaker notes. Many teams replace the illustrative bracket example with a launch from their own plant.
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