PPAP Requirement & Checklist 2026-01-08

Documentation Guidelines and Check Point

Submission Level 3

Part Number & Drawing Revision

Ensure the part number and drawing revision on the PSW match the official drawing.

Completion of All Fields

All fields on the PSW must be filled out correctly.
Information not applicable to the specific part must be marked as “NA”.

Exceptions to Process or PPAP Run

Any exception to the manufacturing process or PPAP run must be noted on the PSW.

Action Plan for Exceptions

Include an action plan to address any exception to drawing and process requirements.

IMDS Information

IMDS number must be included, showing the latest revision submitted to the Material Data System, along with the plant-specific ID.

Molds, Cavities, and Production Process

PSW must specify molds, cavities, and production processes related to the PPAP.

Production Rate

Supplier must note the production rate at which PPAP samples were produced during the significant production run.

Checking Aids

Identify any checking aids used in the everyday processing of the part on the PSW.

Reason for Submission

Clearly identify and confirm the reason for submission (e.g., new part, engineering change).

PPAP Level Compliance

Confirm that the PPAP level corresponds to the requirement stated in the Purchase Order.

Part Weight

Express part weight in kilograms to four significant decimal places (0.0000) using the average from three parts.

Specification Compliance

All dimensional results must be reported according to the specifications on the latest released drawing.

PPAP Production Run Reflection

Dimensional results must reflect measurements taken from the PPAP significant production run.

Report Validity

Dimensional reports must be less than 1 year old (reports older than 12 months are not acceptable).

Sample Quantity and Source

Provide dimensional results for 3 parts per production stream (e.g., each line, machine, cavity) unless otherwise agreed with SDE/SQD.
Samples used for dimensional reports must come from the same batch used for process capability analysis.

Measurement Type

Variable measurements must be provided for all characteristics.
Attribute results are allowed only if variable measurements are not possible.

Ballooned Drawing Linkage

Ballooned dimensions on the latest released drawing must be linked to the dimensional results report.

Serialized PPAP Layout Samples

Dimensions must be measured and reported from serialized PPAP layout samples.

Report Authentication

Dimensional report must be dated and signed.

Additional Compliance Evidence

If required by SDE/SQD, submit additional evidence for CAD dimensions not shown in the dimensional report (e.g., 3D scanning, point cloud inspection, material thickness sectional analysis).

Special Requirements for Casted/Molded Parts

For casted and injection-molded parts and assemblies (e.g., valves), submit material flow simulations, fill studies, including process parameters and CT-analysis for final parts.

Technical Cleanliness Test Report

If the drawing requires a technical cleanliness test report, it must be included.

Submission Format

Material and performance test results must be submitted using the official AIAG format (CFG-1004 & CFG-1005) or an equivalent approved format.
For VDA, ensure compliance with VDA Volume 2 Annex requirements for material and performance documentation.

Chemical Composition Verification

Reports must show actual chemical content values compared to specification limits.
Include full traceability to material standards (e.g., DIN, ISO, SAE) as required by VDA.

Pass/Fail Assessment

Test reports must include a clear pass/fail assessment from the accredited testing source.
VDA requires documented evidence of conformity for all performance characteristics.

Performance Test Evidence

Provide results for all specified performance tests (e.g., mechanical, thermal, corrosion resistance) according to drawing and specification requirements.
For VDA, include test method references and test conditions in the report.

Certification & Traceability

Material certificates must include supplier name, batch/lot number, and heat number for traceability.
VDA additionally requires linkage to production batch and PPAP samples.

Document Authentication

Reports must be dated, signed, and issued by an authorized laboratory or internal quality department.
For VDA, ensure laboratory accreditation details are included (e.g., ISO/IEC 17025 compliance).

Appearance Approval

Visual inspection must confirm compliance with the latest released drawing and customer-specific requirements.
Include color, gloss, texture, and surface finish verification against approved master samples or specifications.
For VDA, ensure documentation of appearance approval report and linkage to design release status.

Haptics (Touch & Feel)

Verify tactile properties such as surface roughness, softness, grip, and ergonomic feel according to specification.
Document test method and acceptance criteria (e.g., tactile comparison to reference samples).
VDA requires subjective evaluation protocols and objective measurement data where applicable.

Acoustics (Noise & Sound Quality)

Confirm compliance with noise level, vibration, and sound quality requirements defined in the drawing or specification.
Include test results from sound measurement equipment or NVH (Noise, Vibration, Harshness) analysis.
VDA mandates test conditions, equipment calibration details, and pass/fail criteria in the report.

Smell (Odor Evaluation)

Conduct odor tests according to OEM-specific standards (e.g., VDA 270 for odor testing).
Document test method, panel evaluation results, and compliance status.
AIAG PPAP requires odor evaluation if specified in the customer requirements; VDA requires full traceability to test protocol.

Master Sample Reference

Maintain and reference approved master samples for appearance, haptics, acoustics, and smell evaluations.
Ensure samples are dated, signed, and stored under controlled conditions.

Documentation & Traceability

Reports must be dated, signed, and include test source accreditation details (e.g., ISO/IEC 17025 compliance).
Link all evaluations to PPAP submission level and production batch traceability.

Quantity and Submission

Submit the required number of sample parts as specified in the Purchase Order or customer-specific requirements.
AIAG typically requires one master sample and additional samples for testing; VDA may require multiple samples per cavity or production line.

Master Sample Identification

At least one approved master sample must be retained by the supplier and one by the customer.
Each master sample must be clearly labeled, dated, and signed by the responsible quality authority.

Traceability

Samples must be traceable to the PPAP submission batch and production run.
Include serial numbers, lot numbers, and production date on the sample identification.

Condition and Preservation

Samples must be in final production condition, including all surface treatments, coatings, and finishes.
Ensure proper packaging to prevent damage, contamination, or corrosion during shipment.

Documentation Linkage

Each sample must correspond to the dimensional results report, material certification, and appearance approval documents submitted in the PPAP package.
For VDA, ensure linkage to Cover Sheet and Part Submission Warrant.

Special Characteristics Verification

Samples must demonstrate compliance with all special characteristics (e.g., safety, regulatory, functional features) as defined in the drawing and DFMEA/PFMEA.

Retention Period

Supplier must retain master samples for the duration specified by the customer or program life, typically until part obsolescence.

Additional Requirements (VDA Specific)

For multi-cavity tools or multiple production lines, submit samples from each cavity/line.
Provide evidence of conformity for appearance, haptics, acoustics, and odor evaluations if applicable.

Function Analysis-Based Test Planning

Define test cases based on the function analysis step of the AIAG & VDA 7-step FMEA approach.
Ensure all intended functions and interfaces are covered.

Verification of Functional Requirements

Each function must be tested under normal and boundary conditions.
Include both nominal and failure scenarios derived from the failure analysis step.

Traceability to DFMEA/PFMEA

Test cases must be traceable to identified failure modes, effects, and causes.
Action Priority (AP) ratings should guide the prioritization of functional tests.

System Response Validation

Validate system behavior under fault conditions using the Supplemental FMEA for Monitoring and System Response.
Include diagnostics, fault detection, and mitigation strategies.

Compliance with Control Plan

Functional tests must align with the control methods defined in the Control Plan (APQP element).

Latest Released Drawing

The latest drawing released by Customer must be included in the PPAP submission package.
This requirement applies regardless of who holds design responsibility (supplier or customer).
Drawings must be officially released and controlled per the design record requirements.

Ballooning and Numbering of Dimensions

All dimensions, excluding information-only notes, must be ballooned and numbered.
This includes:
- Reference dimensions
- Basic dimensions
- Material specifications
- Drawing notes
Where a single callout references multiple features, each individual feature must be ballooned.

Dimensional Verification

All ballooned dimensions must be verified during dimensional inspection.
Results must be documented in the Dimensional Results Report (per PPAP requirements).
Ensure traceability between balloon numbers and inspection results.

Specification Compliance

Verify that all material specifications and special characteristics identified in the drawing are included in the inspection plan.
Special characteristics must be marked according to AIAG & VDA guidelines (e.g., SC, CC symbols).

Document Control

Maintain revision control for all drawings and specifications.
Ensure that the PPAP submission reflects the current approved revision level.

Customer-Specific Requirements

Incorporate any additional documentation or marking requirements specified by the customer.
Confirm compliance with customer-specific PPAP checklists.

Design Responsibility Confirmation

Confirm if the supplier is responsible for design as stated in the Nomination Letter or Purchase Order (PO).
If not design responsible, ensure relevant sections of Customer-provided DFMEA are included.

Inclusion of Design Functions

DFMEA must include design functions for every component.
Functions should be clearly defined and measurable.

Failure Mode Definition

List failure modes in physical, technical, and measurable terms.
Avoid vague descriptions; use precise engineering language.

Effects of Failure

Effects must address:
- Impact on each part
- Next higher assembly
- System and vehicle level
- Customer requirements
- Government regulations

Corrective Actions

Assign corrective actions, responsibilities, and completion dates for:
- High severity ratings (≥ 8)
- High Action Priority (AP) or Risk Priority Numbers (RPN)

Special Product Characteristics

Identify potential special product characteristics (e.g., Critical, Key, Significant, PTC).
Mark these characteristics per AIAG & VDA guidelines.

Causes and Mechanisms

Identify potential causes and/or mechanisms of failure for all failure modes.
Ensure linkage between cause, failure mode, and effect.

Recommended Actions

If no recommended actions exist, explicitly state “None” in the recommended actions column.
Maintain transparency and completeness in documentation.

Traceability

Ensure DFMEA is linked to Design Record, Specifications, and Control Plan.
Maintain revision control and update DFMEA as design changes occur.

Change Request Approval

Include a formal Change Request for Customer approval for any exceptions in meeting:
- Drawing requirements
- Production process requirements
This includes exceptions related to:
- Equipment
- Tooling
- Process
- Material
- Gauging
- Packaging

Engineering Change Documentation

Provide an Engineering Change Document detailing:
- Changes not yet recorded in the official design record
- Modifications already incorporated in the part, product, or tooling at the time of PPAP submission
Ensure documentation includes:
- Description of change
- Reason for change
- Impact analysis (on product, process, and quality)
- Approval status and signatures

Traceability

Maintain full traceability between:
- Change request
- Engineering change document
- Updated design record and process documentation
Ensure revision levels are clearly identified.

Compliance with AIAG & VDA

Changes must follow the AIAG PPAP requirements for Level 3 submission when applicable.
Align with VDA 2 (Production Process and Product Approval) for German OEMs:
- Document all deviations and approvals
- Include risk assessment updates in DFMEA/PFMEA if change affects design or process

Customer Notification

Notify customer of all changes per contractual and regulatory requirements.
Obtain written approval before implementing changes in production.

IMDS Submission

Supplier must submit IMDS data to the specific Customer IMDS ID as designated.
Submission must occur prior to PPAP approval and production release.

Part Number and Drawing Number Accuracy

IMDS entry must match:
- Part number (as shown in the Purchase Order)
- Drawing number (as per the latest released design record)
Ensure consistency between IMDS data and PPAP documentation.

Weight and Material Composition

Reported weight and basic material composition must:
- Match engineering drawing requirements
- Reflect actual part configuration and material specifications
Validate against design record and bill of materials.

Compliance with ELV Directive

IMDS data must comply with:
- Material Data System requirements
- End-of-Life Vehicle (ELV) Directive (2000/53/EC)
Ensure no prohibited substances (e.g., lead, mercury, cadmium, hexavalent chromium) beyond allowable limits.

Approval from Customer

Obtain formal IMDS approval from Customer before PPAP submission.
Maintain documentation of IMDS ID number and approval status in the PPAP package.

Traceability

Ensure IMDS data is linked to:
- Part number
- Drawing revision
- Material specifications
Maintain revision control for any changes in material composition.

Process Flow Alignment

All operations from the Process Flow Chart must be identified and listed sequentially in the PFMEA.
Ensure consistency between process flow, PFMEA, and Control Plan.

Ballooned Features Inclusion

All ballooned/numbered features from the design record must be included in the PFMEA.
Maintain traceability between design features and process controls.

Failure Mode Specificity

Failure modes must be listed in specific, measurable terms.
Example: Separate lines for “over the upper limit” and “under the lower limit” rather than generic “dimension out of spec.”

Effects of Failure

Effects must address:
- Impact on the part
- Next higher assembly
- System-level implications
Include customer and regulatory considerations where applicable.

Recommended Actions

If no recommended actions exist, explicitly state “None” in the recommended actions column.
Maintain transparency and completeness.

Special Characteristics

Identify and address all Special Characteristics (e.g., Critical, Key, Significant, PTC) in the PFMEA Characteristic column.
Ensure alignment with Control Plan and inspection strategy.

Severity, Occurrence, Detection Rankings

Apply rankings per AIAG & VDA PFMEA Manual recommendations.
Use Action Priority (AP) for prioritizing corrective actions instead of traditional RPN.

Document Title and Identification

PFMEA title must include:
- Correct part name
- Part number
- Engineering change level
- Document release status
- Revision date

Traceability

Ensure PFMEA links to:
- Process Flow Diagram
- Control Plan
- Design FMEA (where applicable)
Maintain revision control for all updates.

Complete Sequence of Operations

Process Flow must include:
- Receiving
- Transportation
- Storage
- Subcontracted services
- Alternate paths (rework, repair, backup)
- Labeling and shipping
- GP-12 Safe Launch activities
  - Must include appearance items, all of the Special characteristics and labeling.

Outsourced Processes

Clearly identify any outsourced process and include the name of the sub-supplier.

Consistency Across Documents

Details listed on the Process Flow must be carried over consistently into:
- Control Plan
- PFMEA
Ensure:
- Part/Process numbers match
- Process names and operation descriptions match
- Special characteristic designations match across all three documents.

Document Identification

Title on Process Flow must include:
- Correct part name
- Part number
- Engineering change level
- Document release status
- Revision date

Balloon Features

Process Flow must include all ballooned features and indicate where these features are created in the process.

Traceability

Maintain linkage between Process Flow, PFMEA, and Control Plan for audit and compliance.
Ensure revision control for updates.

Alignment with Process Flow

Control Plan must accurately list flow chart operations with all process characteristics and controls used for controlling the process.
Ensure consistency between Process Flow, PFMEA, and Control Plan.

GP-12 / Safe Launch

Control Plan must have GP-12/Safe Launch separately identified.
Clearly list what is inspected on the parts during Safe Launch, including:
- Appearance items
- Special characteristic
- Dimensional Results (DR)
- Product Quality Checks (PQC)
- Labeling requirements

Ballooned Features

Include all ballooned/numbered features from the design record.
Link balloon numbers to product characteristics and tolerances.

Product Characteristics and Specifications

Accurately list:
- Desired product characteristics and tolerances (with balloon numbers from prints)
- All material and engineering specifications from the drawing

Equipment and Gauging

Clearly list:
- Production equipment numbers/descriptions
- Part-specific gauges
- Test equipment used during production

Measurement and Reaction Plans

Control Plan must refer to:
- A documented measurement procedure
- A documented containment procedure for nonconforming products in reaction plans

PFMEA Linkage

All controls identified in PFMEA must be carried out and listed in the Control Plan.

Sample Size and Frequency

Document sample sizes and inspection frequencies appropriately.

Document Identification

Title must include:
- Correct part name
- Part number
- Engineering change level
- Document release status
- Revision date

Additional Requirements

Control Plan must refer to:
- Annual layout
- GP-12
- Technical Cleanliness inspection requirements

Coverage of DR and PQC, Special characteristic

Supplier must submit Initial Process Capability Studies for all:
- Dimensional Results (DR)
- Product Quality Checks (PQC)
- Special characteristic

Representation of All Production Streams

Studies must represent each unique production process, including:
- Duplicate assembly lines or work cells
- Each position of a multiple cavity die, mold, tool, or pattern

Data Source

Capability/performance data must come from a significant production PPAP run, such as:
- Production Trial Run
- Run-at-Rate

Dimensional Data Correlation

Dimensional report data must fall within the distribution of the capability data.
Dimensional results must be representative of the capability run.

Sample Size

For multiple production streams:
- Submit studies for at least 30 samples from each unique production stream.
If insufficient data:
- Agree on a suitable plan between supplier and corporate representative.

Capability Analysis

Provide capability/performance plots/charts:
- Preferably Six Pack analysis using Minitab or similar software.
Include:
- Raw data for process capability
- Feature name, part name, and gauging method/gauge details

Corrective Action

If capability results do not meet requirements:
- Provide a corrective action plan, including 100% inspection until process stability is achieved.

Capability Criteria

For normal distribution and stable processes:
- Meet criteria stated in Quality Management Requirements, Regulation of Special characteristic
- Typically:
  - Cpk ≥ 1.67 for critical characteristics
  - Cpk ≥ 1.33 for other characteristics

Scope of GR&R

Include Gage R&R studies for all new or modified gauges, measurement, and test equipment.
GR&R is mandatory for all gages used to check Special characteristic, DR and PQC features during in-process inspection.
Preferred method: Minitab ANOVA GR&R.

Tolerance Band

GR&R tolerance band must be equal to or tighter than the tolerance on the drawing dimension.

Acceptance Criteria

Follow GR&R acceptance criteria:
- <10% → Acceptable
- 10% to 30% → Acceptable with action plan for improvement
- >30% → Rejectable

Distinct Categories (ndc)

Number of Distinct Categories (ndc) index must be ≥ 5 on GR&R studies.

Variable GR&R Study

Preferably performed with:
- 3 operators
- 10 parts
- 3 repetitions (3 × 10 × 3 format)

Attribute Study

Preferably performed with:
- 20 parts (10 good, 10 bad)
- 2 operators
- 2 trials

Resolution of Measurement Devices

Measurement devices must have higher resolution than the print requirement.
- Example: Print shows X.XX → Device must measure X.XXX.

Documentation

Include:
- GR&R results and summary
- Raw data
- Feature name, part name, and gauging method/gauge details
Provide correlation analysis if multiple measurement systems are used.

Run at Rate Execution

Conduct a Run at Rate during the PPAP submission phase.
Run must represent normal production conditions, including:
- Standard operators
- Approved equipment and tooling
- Normal shift patterns
- Standard material and packaging

Capacity Verification

Verify that the production process can meet customer-required capacity.
Document:
- Planned production rate (parts per hour/day)
- Actual achieved rate during the run
- Any bottlenecks or constraints identified

Duration and Sample Size

Run at Rate should be long enough to:
- Validate process stability
- Collect representative data for capability studies
Typically includes significant production quantity (e.g., 300 parts or more depending on customer requirements).

Data Collection

Record:
- Start and end time of the run
- Total parts produced
- Scrap and rework quantities
- Downtime events and reasons

Documentation

Submit a Run at Rate Report including:
- Part number and description
- Process flow reference
- Equipment and tooling used
- Operator details
- Achieved production rate vs. required rate
- Observations and corrective actions (if needed)

Linkage to PPAP

Ensure consistency between:
- Run at Rate results
- Initial Process Capability Studies
- Control Plan and PFMEA
Any deviations must be addressed with corrective actions.

Customer Approval

Obtain formal approval from the customer for Run at Rate and capacity verification results before full production release.

Approved Packaging Form

Supplier must submit a copy of the approved packaging form from the division.
Ensure the form reflects:
- Correct part number
- Revision level
- Packaging configuration approved by the customer

Packaging Instructions

Submit a copy of packaging instructions, including:
- Container type and size
- Quantity per container
- Protective measures (e.g., dunnage, separators)
- Labeling details and placement

Labeling Requirements

Labels must include:
- Part number and description
- Revision level
- Quantity
- Supplier name and plant code
- Customer-specific information (e.g., barcodes, QR codes)
Ensure compliance with customer labeling standards (AIAG B-10 or OEM-specific).

Traceability

Identify which information on the label is traceable back to raw material and date of manufacturing process.
Include:
- Lot number or batch number
- Date code
- Serial number (if applicable)

Consistency

Packaging and labeling details must align with:
- Control Plan
- Process Flow Diagram
- PFMEA (for handling and storage risks)

Document Identification

Approved packaging data sheet must include:
- Part name
- Part number
- Engineering change level
- Document release status
- Revision date

PPAP Completion Verification

Confirm that sub-supplier PPAPs are completed and approved before final PPAP submission to the customer.
Maintain evidence of approval (e.g., signed PSW, approval letter).

Document Availability

Ensure sub-supplier PPAP documentation includes:
- Dimensional Results
- Material and Performance Test Results
- Process Flow Diagram
- PFMEA
- Control Plan
- IMDS submission confirmation

PSW Compliance

Verify that Part Submission Warrant (PSW) from sub-supplier:
- Matches part number and drawing revision
- Includes IMDS number and latest revision
- Lists molds/cavities and production process details
- Notes production rate during PPAP run
- Identifies checking aids used in production
- States part weight in kilograms to four decimal places (0.0000)

Traceability

Ensure sub-supplier PPAP status is traceable in your PPAP package.
Include sub-supplier PPAP approval date and revision level.

Risk Management

If sub-supplier PPAP is pending or incomplete:
- Document risk assessment
- Implement containment or interim measures
- Obtain customer agreement for any exceptions

Alignment with AIAG & VDA

Follow AIAG PPAP manual and VDA 2 requirements for sub-supplier documentation.
Ensure consistency across all linked documents (PSW, IMDS, PFMEA, Control Plan).

Applicable CQI Self-Assessment

Supplier must submit updated CQI self-assessment results for applicable processes:
- CQI-9: Heat Treat System Assessment
- CQI-11: Plating System Assessment
- CQI-12: Coating System Assessment
Assessments must be completed per AIAG guidelines and reflect current process conditions.

Corrective Action Plan

For any non-satisfactory items identified in the CQI assessment:
- Submit a corrective action plan detailing:
  - Root cause analysis
  - Action steps
  - Responsible person
  - Target completion date
Ensure follow-up and closure of all corrective actions.

Audit Frequency

Perform CQI self-assessments at least annually or as required by customer-specific requirements.
Maintain records for audit verification.

Traceability

Link CQI audit results and corrective actions to:
- Control Plan
- PFMEA
- Process Flow Diagram
Ensure alignment with PPAP documentation.

Compliance Verification

Confirm that all CQI requirements are met before PPAP approval.
Include CQI audit summary and corrective action status in the PPAP submission package.

Internal Laboratory

For measurements/tests performed at supplier internal labs:
- Provide a Lab Scope detailing:
  - Types of tests performed
  - Equipment used
  - Calibration standards
  - Environmental conditions maintained

External Laboratory

For measurements/tests performed at external labs:
- Provide lab accreditation certificates, such as:
  - ISO/IEC 17025
  - NIST traceability
  - A2LA certification
- Ensure accreditation is valid and covers the scope of testing performed.

Quality Management Certification

Supplier must provide a valid Quality Management System certificate, such as:
- IATF 16949 (formerly ISO/TS 16949)
- ISO 9001
Certificate must be current and issued by an accredited certification body.

Traceability

Ensure all test reports reference:
- Lab name and accreditation details
- Equipment calibration status
- Part number and revision level

Document Control

Maintain copies of lab scope, accreditation certificates, and QMS certificates in the PPAP submission package.
Ensure revision control and validity dates are clearly indicated.