PPAP Requirement & Checklist
The AIAG/VDA PPAP Level 3 Checklist is a comprehensive guideline for suppliers to ensure full compliance with global automotive quality standards during Production Part Approval Process (PPAP) submission. This checklist integrates AIAG’s document-driven approach and VDA’s risk-based methodology, providing a unified framework for quality assurance.
KIMEC|Expert Group 
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 MPT 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 MPT or 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 MPT-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
- Submit a corrective action plan detailing:
- 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
- Provide a Lab Scope detailing:
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.
- Provide lab accreditation certificates, such as:
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.
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