PPAP sampling (Level 1 to 3), Production Part Approval Process

PPAP is a customer-driven verification process (AIAG manual) that ensures series products can be manufactured reproducibly to specification. The result is part approval via the PSW, Part Submission Warrant (sample approval).

PPAP level	Brief description	Typical use	Submission to the customer
Level 1	PSW (warrant), all other evidence remains with the supplier	Low risk, standard/catalogue parts, resubmission without changes	PSW + label/sample label if required
Level 2	PSW + limited supporting data	Moderate risk, few critical characteristics	PSW, product-related documents (e.g. dimensional report, material tests) + 1 to 3 sample parts
Level 3	PSW + complete supporting data	New parts, dimensionally critical components, safety/regulatory requirements	PSW, complete PPAP package + sample parts + master sample/gauge evidence

Note: levels 4/5 also exist (customer-specific or on-site audit); in the sealing sector, levels 1 to 3 predominate.

#	Element	Content / example for seals	Submission (L1/L2/L3)
1	Design Record	Drawing with tolerances, material code, critical characteristics (✱/CC/SC)	- / ✓ / ✓
2	ECNs	Approved change levels	- / ✓ / ✓
3	Customer Engineering Approval	Advance approvals, if required	- / (✓) / (✓)
4	DFMEA	For customer-owned design, otherwise “not applicable”	- / - / (✓)
5	Process Flow Diagram	Goods receipt → compound/sheet → cutting/punching/moulding → QA → dispatch	- / ✓ / ✓
6	PFMEA	Risks: dimensional deviation, hardness/compression set behaviour, flash, mix-ups	- / ✓ / ✓
7	Control Plan	Dimensional/hardness checks, visual inspection, traceability	- / ✓ / ✓
8	MSA	Measurement system analysis (e.g. Shore A, diameter/profile)	- / (✓) / ✓
9	Dimensional Results	Dimensional report on n parts (critical characteristics 100% or n = customer-specific)	- / ✓ / ✓
10	Material / Performance Tests	Material testing, media resistance, KTW-BWGL/WRAS/FDA/UL 94 if applicable	- / ✓ / ✓
11	Initial Process Studies	SPC/Cp Cpk for critical dimensions (target usually ≥ 1.33/1.67)	- / (✓) / ✓
12	Qualified Laboratory	Accreditation evidence for test laboratories	- / (✓) / ✓
13	Appearance Approval	AAR, for parts where appearance matters	- / - / (✓)
14	Sample Production Parts	Sample parts manufactured with series parameters	- / ✓ / ✓
15	Master Sample	Reference part, retained by the supplier	- / - / (✓)
16	Checking Aids	Gauges/test fixtures, calibrations	- / - / (✓)
17	Packaging Approval	Approved packaging/labels/traceability	- / (✓) / ✓
18	PSW, Warrant	Approval document (with deviations, if any)	✓ / ✓ / ✓

Exact submission requirements according to customer-specific requirements (CSR). ”(✓)” = frequently required.

• Kick-off & CSR check: clarify customer requirements (level, sample size, labels, IMDS, special approvals).

• Process/inspection planning: define flow, PFMEA, control plan, test equipment/gauges.

• Sample production: components made with series parameters; carry out tests/analyses (dimensions, hardness, function, media/fire behaviour if applicable).

• Documentation package: consolidate the PPAP documents according to the level; prepare the PSW.

• Submission & review: digital submission, clarification of queries, final approval.

Practical tip: define critical dimensions early (drawing/CC/SC) and validate the measurement concept (MSA/SPC) before sample production. This saves iteration loops.

Aspect	PPAP (AIAG)	VDA 2 (PPF)
Approval document	PSW (Part Submission Warrant)	PPF forms (e.g. VDA 2 annex)
Levels	Level 1 to 5	Submission levels A-D (customer-specific)
Critical characteristics	SC/CC, customer-specific symbols	Special characteristics, VDA conventions
Relevance for seals	Widely used internationally	Very common in the D-A-CH automotive sector

• How many parts do I need for the dimensional report? This is defined by the customer (CSR). Often 5 to 30 parts, critical characteristics 100% if required.

• Does IMDS have to be submitted? If required by the customer (especially in automotive). We supply IMDS entries on request.

• Does PPAP approval remain valid after a change of material? Changes to formulation, hardness or colour must be notified and often require resubmission.

We prepare PPAP packages to level 1 to 3, including dimensional reports, MSA/SPC, material and functional tests and PSW submission.