How do you align PPAP dimensional reports with other PPAP elements and requirements?

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Production Part Approval Process (PPAP) is a quality assurance method that verifies that a supplier can produce parts that meet the customer's specifications and requirements. One of the key elements of PPAP is the dimensional report, which shows the actual measurements of the part and compares them to the design specifications. How do you align PPAP dimensional reports with other PPAP elements and requirements? Here are some tips to help you create accurate and consistent dimensional reports for PPAP.

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Ashutosh Kumar Dubey

Manufacturing Development Engineer @ Humanetics Group | New Product Development and Manufacturing Processes | ISO…
Akshay Ramanath Hegde

Lead auditor |New Product Development & Quality Assurance | Supplier Development Expert |IRCA Approved Lead Auditor |…

1 Choose the right measurement method

Depending on the complexity and size of the part, you may need to use different measurement methods, such as coordinate measuring machines (CMM), calipers, gauges, or optical devices. You should choose the measurement method that is most suitable for the part and the specification, and that can provide reliable and repeatable results. You should also follow the measurement system analysis (MSA) guidelines to ensure that your measurement method is valid and capable.

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Akshay Ramanath Hegde

Lead auditor |New Product Development & Quality Assurance | Supplier Development Expert |IRCA Approved Lead Auditor | ISO 9001 | 14001 | 45001 | IATF 16949 | VDA6.3 | LSSGB Certified
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Aligning PPAP dimensional reports with other PPAP elements and requirements involves ensuring that the measurements and specifications outlined in the dimensional reports match the criteria set forth in the rest of the PPAP documentation. This means that the measurements taken for parts or components should be consistent with the design specifications and requirements detailed in drawings, blueprints, or other technical documents. Additionally, the dimensional reports should align with any applicable standards or customer-specific requirements. By ensuring this alignment, manufacturers can demonstrate that their parts meet the necessary dimensional criteria and are compliant with the overall PPAP submission.

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Ashutosh Kumar Dubey

Manufacturing Development Engineer @ Humanetics Group | New Product Development and Manufacturing Processes | ISO 9001:2015 QMS Internal Auditor | ISO/IEC 17025:2017 | Industry 4.0 |
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Choose the Right Measurement Method Depending on part complexity, utilize suitable measurement methods like CMM, calipers, gauges, or optical devices. Prioritize reliability and repeatability. Adhere to MSA guidelines to validate method accuracy and capability.

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2 Follow the dimensional layout

The dimensional layout is a document that shows the location and orientation of all the critical features and dimensions of the part. It also indicates the measurement method, the tolerance, and the sample size for each dimension. You should follow the dimensional layout when performing the measurements and recording the data. The dimensional layout should be consistent with the part drawing and the control plan, which are other PPAP elements that describe the design and process requirements of the part.

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Ashutosh Kumar Dubey

Manufacturing Development Engineer @ Humanetics Group | New Product Development and Manufacturing Processes | ISO 9001:2015 QMS Internal Auditor | ISO/IEC 17025:2017 | Industry 4.0 |
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Follow the Dimensional Layout The dimensional layout depicts critical features, measurement methods, tolerances, and sample sizes for each dimension. Adhere to it during measurements and data recording. Ensure consistency with the part drawing and control plan, aligning with design and process requirements.

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3 Use the appropriate format and software

The dimensional report should be formatted in a clear and standardized way, following the customer's or the industry's requirements. You should use the appropriate software to generate the dimensional report, such as Excel, Minitab, or other statistical tools. The software should be able to calculate the mean, standard deviation, range, and other statistical parameters of the measurements, as well as generate charts and graphs to show the distribution and variation of the data. The software should also be able to compare the measurements to the specifications and indicate whether they are within or outside the tolerance limits.

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4 Document the results and actions

The dimensional report should document the results of the measurements and any actions taken to correct or improve them. For example, if some measurements are out of specification, you should identify the root cause of the problem, such as a defect in the material, a tool wear, or a process variation. You should also document the corrective actions taken, such as reworking, replacing, or adjusting the part, tool, or process. You should also document any deviations or waivers granted by the customer for non-conforming parts.

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Ashutosh Kumar Dubey

Manufacturing Development Engineer @ Humanetics Group | New Product Development and Manufacturing Processes | ISO 9001:2015 QMS Internal Auditor | ISO/IEC 17025:2017 | Industry 4.0 |
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Use Appropriate Format and Software Format dimensional reports according to customer or industry standards. Utilize software like Excel, Minitab, or statistical tools. Ensure software capabilities include statistical parameter calculation, chart/graph generation, and comparison to specifications. This aids in clear data presentation and adherence to tolerance limits.

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5 Submit and review the dimensional report

The dimensional report is one of the PPAP documents that you need to submit to the customer for approval. You should submit the dimensional report along with other PPAP documents, such as the part submission warrant (PSW), the material test results, the process flow diagram, the failure mode and effects analysis (FMEA), and the process capability studies. You should also review the dimensional report with the customer and address any questions or feedback they may have. You should ensure that the dimensional report is aligned with the customer's expectations and requirements, and that it demonstrates that your part meets the quality standards.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ashutosh Kumar Dubey

Manufacturing Development Engineer @ Humanetics Group | New Product Development and Manufacturing Processes | ISO 9001:2015 QMS Internal Auditor | ISO/IEC 17025:2017 | Industry 4.0 |
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Submit and Review Dimensional Report Include the dimensional report in PPAP submission alongside documents like PSW, material test results, FMEA, and process capability studies. Review report with customer, addressing questions or feedback. Ensure alignment with customer expectations and quality standards to demonstrate part compliance.

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How do you align PPAP dimensional reports with other PPAP elements and requirements?

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1 Choose the right measurement method

2 Follow the dimensional layout

3 Use the appropriate format and software

4 Document the results and actions

5 Submit and review the dimensional report

6 Here’s what else to consider

Production Part Approval Process (PPAP)

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