How do you verify and validate the impact of engineering changes on your PPAP submissions and approvals?

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Production Part Approval Process (PPAP) is a quality assurance method that ensures that suppliers meet the specifications and requirements of their customers. PPAP is widely used in the automotive industry and other sectors that have high safety and reliability standards. But what happens when you need to make engineering changes to your product or process? How do you document them and ensure that they do not affect the quality and performance of your PPAP submissions and approvals? In this article, we will explain how to document engineering changes for PPAP in six steps.

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1 Identify the change

The first step is to identify the type and scope of the change that you need to make. Is it a design change, a material change, a process change, or a combination of them? How does it affect the function, appearance, or performance of your product? How does it impact the customer requirements and expectations? You need to answer these questions and document them clearly and accurately.

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2 Evaluate the impact

The second step is to evaluate the impact of the change on your PPAP elements. Depending on the level of the change, you may need to update some or all of your PPAP documents, such as design records, engineering specifications, process flow diagrams, control plans, measurement system analysis, dimensional reports, material test reports, and performance test results. You need to assess the risk and severity of the change and determine the appropriate PPAP level and submission requirements.

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EUR ING | (Ing.) | IEng MIET | CQP MCQI | MPM-FAAPM | CPM-IAPM | BVOAD | CPO | CSSBB | SRMP-C
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One thing I’ve found helpful is that PPAP highlights the proof or evidence collected through APQP. In my experience, we should first understand how it applies in evaluating the impact which is as follows: 1. Validated results from the first trial run support the assertion that quality of delivery is expected. 2. The trial run must represent the production environment, with correct tools, machines, processes, personnel, and conditions that may affect part quality.

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3 Communicate with the customer

The third step is to communicate with your customer and inform them of the change. You need to explain the reason, nature, and effect of the change and provide them with the updated PPAP documents for their review and approval. You also need to agree on the timing and method of the change implementation and verification. You should maintain a clear and consistent communication with your customer throughout the change process.

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4 Implement the change

The fourth step is to implement the change according to the agreed plan and specifications. You need to follow the standard procedures and guidelines for making engineering changes and document the actions and results. You also need to ensure that the change is properly controlled and validated in your production process and that it does not introduce any new issues or defects.

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5 Verify the change

The fifth step is to verify the change and confirm that it meets the customer requirements and expectations. You need to perform the necessary tests and inspections to validate the quality and performance of your product after the change. You also need to collect and analyze the data and evidence to support your PPAP submission and approval. You should document the verification methods and results and report any deviations or problems.

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6 Submit the PPAP

The final step is to submit your PPAP package to your customer for their approval. You need to include all the relevant PPAP documents, such as the part submission warrant, the engineering change notice, the updated design records, the updated process documents, the updated test reports, and any other documents required by your customer. You also need to provide samples of your product for their evaluation and approval. You should follow up with your customer and address any feedback or questions they may have.

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How do you verify and validate the impact of engineering changes on your PPAP submissions and approvals?

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1 Identify the change

2 Evaluate the impact

3 Communicate with the customer

4 Implement the change

5 Verify the change

6 Submit the PPAP

Production Part Approval Process (PPAP)

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