PPAP is one of those automotive requirements that seems straightforward until a submission gets kicked back. The most common reason? Submitting the wrong level, or a Level 3 package missing key elements. Here is how the submission levels actually work, what each requires, and where suppliers most often go wrong.
What PPAP Is
PPAP — the Production Part Approval Process — is the automotive industry’s documented method for demonstrating two things: that a supplier fully understands the engineering design requirements, and that their manufacturing process can consistently produce conforming parts. It is a required part of IATF 16949 supply chains. When a customer says “submit PPAP,” they are asking you to prove, on paper, that your process is capable and controlled.
The Five PPAP Levels
| Level | What You Submit |
|---|---|
| Level 1 | Part Submission Warrant (PSW) only. The customer retains the supporting records. |
| Level 2 | PSW plus a limited number of supporting records and samples. |
| Level 3 | PSW plus complete supporting data, including all 18 PPAP elements. This is the default level — what most customers require when they do not specify. |
| Level 4 | PSW plus other requirements as defined by the customer. |
| Level 5 | PSW plus records and samples available for review at the supplier’s manufacturing location. |
The key takeaway: Level 3 is the default. If a customer does not specify a level, assume they want Level 3 with the full documentation package.
The 18 PPAP Elements
A complete Level 3 submission includes all 18 elements:
- Design documentation
- Engineering change documents
- Customer engineering approval
- DFMEA (Design Failure Mode and Effects Analysis)
- Process flow diagram
- PFMEA (Process Failure Mode and Effects Analysis)
- Control plan
- Measurement system analysis (Gage R&R)
- Dimensional results
- Material and performance test results
- Initial process study (Cpk)
- Qualified laboratory documentation
- Appearance approval report
- Sample production parts
- Master sample
- Checking aids
- Customer-specific requirements
- Part Submission Warrant (PSW)
Common Mistakes
Three errors account for most rejected submissions:
- Submitting a Level 1 when the customer requires Level 3. If the requirement is not specified, default to Level 3 rather than the minimum.
- Missing elements in a Level 3 submission. Gage R&R and initial process capability (Cpk) are the two most commonly omitted elements — and they are precisely the ones customers scrutinize.
- Signing the PSW too early. Submitting a Part Submission Warrant with a signature before customer engineering approval has been obtained undermines the entire package.
Getting It Right the First Time
A rejected PPAP delays production launch and damages customer confidence. The fix is discipline: confirm the required submission level before you begin, build the full 18-element package for any Level 3 submission, and verify that your measurement system analysis and capability studies are complete and defensible before the PSW is signed. The core tools — DFMEA, PFMEA, Control Plans, and Gage R&R — are where submissions live or die.
Exceleor provides PPAP training covering all levels, DFMEA, PFMEA, Control Plans, and Gage R&R. → exceleor.com/services