How can you become a PPAP expert?

1 Learn the basics

The first step to becoming a PPAP expert is to learn the basics of the process and its purpose. PPAP is based on the Advanced Product Quality Planning (APQP) framework, which guides the development of new products and processes from design to launch. PPAP is the final stage of APQP, where you verify that the product meets the customer's expectations and requirements. To do this, you need to submit a set of documents and samples to the customer for approval. These documents and samples are known as the PPAP package, and they include information such as design records, material specifications, test results, process flow charts, control plans, and measurement system analysis.

2 Understand the levels and elements

The second step to becoming a PPAP expert is to understand the different levels and elements of the PPAP package. Depending on the customer's request and the complexity of the product, you may need to submit different types of documents and samples. There are five levels of PPAP, ranging from level 1, where you only submit a part submission warrant (PSW), to level 5, where you submit the complete PPAP package and retain all the records at your site. There are also 18 elements of the PPAP package, each of which provides specific information about the product and its quality. You need to know which elements are mandatory, optional, or conditional, and how to prepare them according to the PPAP manual.

3 Follow the procedures and standards

The third step to becoming a PPAP expert is to follow the procedures and standards that govern the PPAP process. These include the PPAP manual, which is published by the Automotive Industry Action Group (AIAG), and the customer-specific requirements (CSR), which are set by each customer according to their needs and preferences. You need to follow the PPAP manual and the CSR closely, as they define the rules, guidelines, and expectations for the PPAP submission. You also need to comply with the relevant quality standards, such as ISO 9001, IATF 16949, and ISO 14001, which ensure that your products and processes meet the industry and regulatory requirements.

4 Use the tools and techniques

The fourth step to becoming a PPAP expert is to use the tools and techniques that help you perform the PPAP tasks effectively and efficiently. These include software applications, such as Excel, Word, PowerPoint, and Minitab, that help you create, organize, and present the PPAP documents and data. They also include statistical methods, such as capability analysis, gauge repeatability and reproducibility (GRR), and failure mode and effects analysis (FMEA), that help you measure, analyze, and improve the quality and reliability of your products and processes. You need to master these tools and techniques, as they enable you to produce accurate, consistent, and professional PPAP packages.

6 Keep learning and improving

The sixth and final step to becoming a PPAP expert is to keep learning and improving your skills and knowledge in the PPAP process. This means that you should always seek to update yourself on the latest changes and developments in the PPAP manual, the CSR, and the quality standards. You should also seek to learn from your experience, mistakes, and best practices, and apply them to your future PPAP projects. You should also seek to expand your scope and challenge yourself with new and complex PPAP assignments. By doing this, you will demonstrate your competence, confidence, and professionalism in the PPAP process, and become a valuable asset to your organization and customers.