PPAP training builds the competence to prepare the file to be submitted to the customer for part approval correctly, so that it is accepted the first time.
PPAP (Production Part Approval Process) is the process of proving that the production process can consistently produce product meeting customer requirements under series conditions. It is published by AIAG; the edition in force is the 4th.
Why do files get rejected?
PPAP is the Core Tool automotive suppliers struggle with most. The majority of rejected files stem not from technical inadequacy but from process mistakes:
The wrong submission level. The level the customer requested and the level submitted do not match. The level is determined by the customer; proceeding on assumption wastes time.
Missing or inconsistent elements. The measurement results do not match the characteristics in the control plan, the risks in the PFMEA are not reflected in the control plan, the MSA study has not been done.
Customer-specific requirements skipped. Every OEM’s PPAP expectations differ, and customer-specific requirements add to the standard elements. Ford, GM, Stellantis and others have their own PPAP documents.
The significant production run condition not met. The samples were not produced under series production conditions, with series equipment and series operators.
The change not notified. A change requiring PPAP was made but not notified to the customer. This is the mistake with the heaviest consequences.
Who should attend?
- Quality engineers and quality managers
- Project and launch officers
- Product and process development engineers
- Measurement and laboratory officers
- Purchasing and supplier quality teams
- Technical personnel responsible for customer relations
- IATF 16949 internal auditors
There are no prerequisites.
Training Content
Fundamentals
- The purpose of PPAP and its place in the supply chain
- When it is required: new part, change, relocation, after suspension
- Its relationship with the APQP phases
- The significant production run concept
The approval elements
The design record, engineering change documents, customer approvals, design and process FMEA, process flow diagram, control plan, measurement systems analysis, dimensional results, material and performance test results, initial process studies, laboratory documentation, appearance approval report, sample parts, master sample, checking aids, customer-specific requirements and the part submission warrant are addressed one by one.
The submission levels
The scope of the five submission levels, which one is used in which case and how it is determined by the customer are explained.
The part submission warrant
Filling out the warrant correctly, weight and result declarations, and managing rejection and interim approval situations are addressed.
Change notification
The change types requiring PPAP, the notification obligation, timing and the customer approval process are covered. This section is the source of the mistakes with the heaviest consequences in practice.
The link with the other tools
The place of FMEA, Control Plan, MSA and SPC outputs within the file and how their mutual consistency is ensured are shown.
Practical exercises
Participants identify gaps in a sample file and fill out a part submission warrant. In in-house programmes your own files are reviewed.
Learning Outcomes
- Preparing and submitting a PPAP file
- Determining the correct submission level
- Establishing consistency between the elements
- Filling out the part submission warrant correctly
- Recognizing and notifying changes that require PPAP
- Detecting file rejection causes in advance
Duration and Participation Options
Duration: 2 days in open-enrolment programmes. In in-house programmes, planned as 1–3 days depending on the scope and depth of the practical work.
Participation type: Open enrolment or in-house.
Training method: In person (at your organization or in our training room), live online, on-demand recording.
Obtaining the manuals: AIAG and VDA publications are copyright-protected and are not provided as part of the training. Participants need access to the current edition.
Dates: Set according to demand.
Certificate of Attendance
Participants who complete the training receive a certificate of attendance. The certificate includes the participant’s name, training scope, date and duration. It can be used as evidence of competence in your competence records and in customer audits.
- APQP Training
- Control Plan Training
- AIAG-VDA FMEA Training
- MSA Training
- Automotive Core Tools — all six tools
Beyond Training: Implementation Support
- Pre-submission review of your PPAP files
- Preparing file templates and checklists
- Building the customer-specific requirement inventory
- Evaluating PPAP files coming from your suppliers
- Setting up the change notification process
You can make use of our consulting services in every area where support is needed.
Frequently Asked Questions About PPAP Training
Which is the current edition of PPAP?
AIAG PPAP 4th edition is in force.
When is PPAP required?
For a new part, an engineering change, relocation of the production site, a supplier or material change, after a prolonged production interruption, and in other cases requested by the customer.
Who determines the submission level?
The customer does. There are five levels and which one will be requested depends on your customer requirements. We recommend getting confirmation instead of proceeding on assumption.
Why do files get rejected most often?
The wrong submission level, inconsistency between elements, skipped customer-specific requirements, samples not produced under series production conditions, and unnotified changes are the most frequent causes.
What does significant production run mean?
The requirement that PPAP samples be produced with series production equipment, series tooling, series operators and at series rate. PPAP cannot be submitted with parts produced under prototype conditions.
Are every customer’s PPAP expectations the same?
No. Customer-specific requirements add to the standard elements; many OEMs have their own PPAP documents. You need to check your contracts and CSR documents.
Should we also evaluate the PPAP files coming from our suppliers?
Yes. In the supply chain, part approval is your responsibility; archiving the file from your supplier is not enough, you need the competence to evaluate it.
How long does PPAP training take?
Open-enrolment programmes take 2 days. In-house programmes are planned as 1-3 days depending on content density.