Reference
What is PPAP? Meaning, process and the 18 elements
PPAP is how an automotive supplier proves two things in writing: that the part matches the drawing, and that the process making it can repeat that in series. Here is what the acronym means, what is in the package, and who asks for it.
The meaning, in two sentences
PPAP stands for Production Part Approval Process. It is the procedure by which a supplier demonstrates that a production part conforms to the customer's drawing and specification, and that the production process delivers it repeatably under normal series conditions. Until the customer approves that package, series deliveries do not start.
Five parts made slowly and carefully by a skilled operator prove the first point and not the second – which is why process documents belong in the package at all. The manual is published by the AIAG.
Who asks for PPAP – and who asks for something else
No law requires it. The obligation comes from your contract and from IATF 16949, which requires a product and process approval procedure and points to the customer's own requirements for the detail.
- PPAP is asked for by the North American carmakers and their supply chains, and widely across Asia and by internationally organised suppliers.
- PPF to VDA volume 2 – Produktionsprozess- und Produktfreigabe – is the German equivalent, asked for by the German carmakers and their larger suppliers. Same goal, different cut.
If you supply into Germany, expect the German paperwork and the German words for it: Erstmusterprüfbericht (EMPB) for the dimensional report, Vorlagestufe where PPAP says level.
PPAP, PSW, ballooning: the words
| Term | What it means |
|---|---|
| PPAP | the whole approval package, up to 18 elements |
| PSW | Part Submission Warrant: the cover sheet stating what is submitted, why, at which level, signed |
| Dimensional results | the table of every characteristic with nominal, tolerance, readings and verdict – element 9, and the part of the job that takes the longest |
| Ballooned drawing | the customer's drawing with every dimension numbered; those numbers carry the whole report |
How it runs in the shop
- Establish the reason. New part, drawing change, new process, new location, tooling move, requalification – the reason goes on the warrant.
- Ask for the level and the customer-specific requirements. If nothing is stated, level 3 is meant.
- Balloon the drawing. Every characteristic gets its number.
- Run a significant production run – series tooling, series process, series operators. At least six parts for the dimensional report.
- Measure and evaluate every characteristic on every part, with a suitable gauge in valid calibration.
- Assemble the package for the level: what is submitted, what stays on file. That is what the scope planner is for.
- Submit and follow up – customer portal or a document set, then wait for approval or work off the rejection.
The 18 elements
Which of them you actually submit depends on the level and on your customer's requirement matrix. You are normally expected to hold all that apply to your part.
| No. | Element | What it is |
|---|---|---|
| 1 | Design Records | the customer's drawing at the correct revision, ballooned: every dimension numbered |
| 2 | Authorized Engineering Change Documents | the engineering change notices that apply to this revision |
| 3 | Engineering Approval | sign-off by the customer's engineering, sometimes after trials with production parts |
| 4 | Design FMEA | failure modes of the design – only where the supplier owns the design |
| 5 | Process Flow Diagram | every manufacturing step in sequence, from raw material to packaging |
| 6 | Process FMEA | what can go wrong at each step and what is done about it |
| 7 | Control Plan | per characteristic: what is measured, with what, how often, by whom, and the reaction |
| 8 | Measurement System Analysis | evidence that gauge variation is small against the tolerance (gauge R&R) |
| 9 | Dimensional Results | every characteristic with nominal, tolerance, readings and verdict – the report itself |
| 10 | Material and Performance Test Results | material certificate with composition and strength, plus tests such as hardness, torque, leak and corrosion |
| 11 | Initial Process Studies | statistical study of the special characteristics: Pp/Ppk first, Cp/Cpk later |
| 12 | Qualified Laboratory Documentation | proof the laboratory is accredited (ISO/IEC 17025) or approved by the customer |
| 13 | Appearance Approval Report | only where colour, gloss or surface appearance is specified – rarely on turned parts |
| 14 | Sample Production Parts | the physical parts, labelled and traceable to the report |
| 15 | Master Sample | one part signed by both sides and kept for comparison |
| 16 | Checking Aids | purpose-built gauges and fixtures, with photographs and calibration records |
| 17 | Customer-Specific Requirements | whatever the customer adds: portals, formats, material data, company standards |
| 18 | Part Submission Warrant (PSW) | the cover sheet: what is submitted, why, at which level, signed |
The five levels
| Level | What is submitted |
|---|---|
| 1 | the PSW only Simple parts, minor changes, suppliers with a long record. |
| 2 | PSW, sample parts and selected supporting data Which data is up to the customer – usually drawing, dimensional results and material. |
| 3 | PSW, sample parts and complete supporting data The industry default. If the order says nothing, this is what is meant. |
| 4 | PSW and whatever the customer specifies The scope lives in the customer's requirement matrix, not in the manual. |
| 5 | PSW; complete supporting data available for review at the supplier Nothing is shipped – the customer reviews on site. Completeness is still mandatory. |
Level by level: PPAP levels 1 to 5.
What European customers add
Not part of the 18, but regularly required when you supply into Germany:
- IMDS – the material data sheet in the International Material Data System; without an accepted entry European carmakers generally do not approve
- EN 10204 material certificate – which type – 3.1 is common – is stated in the order; the heat number must match the sample parts
- Packaging approval – container, quantity and label, signed off by the customer
- Technical cleanliness – to VDA 19 or ISO 16232, typical for hydraulic and injection parts
- Calibration records – for every gauge that appears in the report
- Substance declarations – RoHS, REACH and conflict minerals
- Requalification – re-checking every characteristic during series production, often yearly
Common questions
- What does PPAP stand for?
- Production Part Approval Process. It is how a supplier proves to an automotive customer that the part matches the drawing and that the series process produces it repeatably. The manual is published by the AIAG.
- What is the difference between PPAP and an inspection report?
- The dimensional report is one element of PPAP – number 9. PPAP is the whole package of up to 18 elements. In German-speaking industry the whole package is often called EMPB, after that one element.
- Is PPAP required by law?
- No. The obligation comes from the contract and from IATF 16949, which requires a product and process approval procedure and refers to the customer's own requirements.
- Which level applies if nothing was agreed?
- In practice level 3: warrant, sample parts and the complete supporting data. What governs is your customer's requirement matrix.
- How many parts must be measured?
- Usually at least six from a significant production run. A capability figure needs far more.
Sources
- Production part approval process, Wikipedia, retrieved 11 September 2026: the 18 elements, the five levels, the minimum of six parts, the ballooned drawing.
- IATF 16949: a product and process approval procedure to customer requirements – paraphrased.
- Our own research into practice at German suppliers (September 2026). Which customer group asks for what describes common practice; it is not a statement about the text of any standard.
Standards are copyrighted and sold by their publishers. We give their content in our own words; what governs is the standard in its current edition and your customer's requirements. No AIAG or VDA form is reproduced here.