PPAP - Production Part Approval Process : Levels of PPAP.

There are 5 levels of PPAP. They are summarized as below :

Note : Table taken from PPAP 4th Edition.

Level 1:

Here we need to submit Part Submission Warrant (PSW) only. If you are supplying aesthetic product to your customer, appearance item clause is applicable. Hence you need to additionally submit AAR (Appearance Approval Report).

Level 2:

The requirement under this level is to submit Part Submission Warrant and limited supporting data submitted to customer. Here limited supported data refers to the following minimum documents :

• Product drawing. 
• Layout Inspection report / Inspection report or PDI as per discussion with customer. Submission of type of dimensional report depends on customer expectations. 
• Lab Test reports (Validation reports) in case of assembly product and as per requirements mentioned in the product drawing.
• Raw material test certificates (RMTC). Now a days, customer demand third party reports (NABL) for material confirmation.
• Sample products (as applicable)
• Appearance approval report, if applicable.
• NABL scope of the lab where the tests are conducted certifying and assuring customer that the testing is carried out from qualified laboratory.
• Part Submission Warrant. 

Level 3:

PPAP 4th Edition mentions "Warrant with product samples and complete supporting data to be submitted to the customer." This level 3 is normally considered as default level in automotive industries.  Following are required as part of Level 3 requirements.

• Customer Approved product drawing. 
• Design records. If part is proprietary, drawings are not submitted to customer.
• ECN related documents, if applicable
• Design FMEA (DFMEA)
• Process FMEA (PFMEA)
• Process Flow Diagram (Process Flow Chart)
• Control Plan
• Layout Inspection
• SPC Studies (Pp, Ppk studies)
• MSA Studies
• Appearance Approval Report, if applicable
• Qualified Lab documents (NABL scope of the lab wherein the tests were conducted)
• Product Validation Reports (as applicable)
• Material test reports (Third party lab reports)
• Checking Aids is to be retained at supplier end, but should be part of PPAP document. In almost all cases, customer demand this as additional requirement and wants supplier to submit the checking aids document.
• Customer Specific Requirement Records
•  Part Submission Warrant (PSW)
• Samples products
• Master Sample is retained at supplier (sign off done by customer, as applicable)
• Bulk requirement checklist, if applicable.

Level 4:

PPAP standard mentions "Part submission Warrant and other requirements specified by the customer."  In this level, supplier has to maintain all the documents specified in Level 3 at own premises and only Part Submission Warrant is to be submitted. 

If bulk material is applicable, then bulk material checklist also needs to accompanied along with PSW. The documents are to be submitted to customer on request as and when demanded.

Level 5:

PPAP Standard mentions " Par Submission Warrant with product samples and complete supporting data reviewed at supplier premises. Here the supplier need not submit any document to customer. During PPAP audit, customer audits the process and reviews the documents and sign off PSW if all requirements are fulfilled.

Hope all is understood, if any queries, please revert with your queries on qualitykatta@gmail.com.