APQP/PPAP - Advanced Product Quality Planning & Production Part Approval

When to Activate This Skill

• "What APQP phase are we in?"

• "Create a phase gate checklist"

• "What PPAP elements are required?"

• "Generate a PSW for [part]"

• "Create a timing plan for [program]"

• "Track open issues for [launch]"

• "What's needed for PPAP Level [X]?"

• "Run readiness review"

Workflow Routing

Workflow Trigger File

PhaseGate "phase gate review", "gate checklist" Workflows/PhaseGate.md

PpapPackage "PPAP elements", "PPAP submission" Workflows/PpapPackage.md

TimingPlan "timing plan", "launch schedule" Workflows/TimingPlan.md

OpenIssues "open issues", "issue tracker" Workflows/OpenIssues.md

APQP Five Phases

Phase 1: Plan and Define Program

Purpose: Determine customer needs and expectations

Key Deliverables:

Deliverable Description Owner

Voice of Customer Customer requirements documented Commercial

Business Plan Program justification, capacity, investment GM

Product/Process Assumptions Initial feasibility assessment Engineering

Product Assurance Plan Quality objectives, reliability goals Quality

Preliminary BOM Initial bill of materials Engineering

Preliminary Process Flow High-level manufacturing concept Mfg Eng

Preliminary Special Characteristics Initial CC/SC identification Quality

Management Support Resource commitment GM

Gate 1 Criteria:

• Customer requirements documented and reviewed

• Feasibility assessment complete

• Resource plan approved

• Risk assessment performed

• Timing plan established

Phase 2: Product Design and Development

Purpose: Develop design to near-final form

Key Deliverables:

Deliverable Description Owner

DFMEA Design Failure Mode Effects Analysis Design Eng

Design for Manufacturability (DFM) Manufacturing input to design Mfg Eng

Design Verification Plan DVP&R creation Design Eng

Engineering Drawings Released with GD&T Design Eng

Engineering Specifications Material, performance specs Design Eng

Prototype Build Sample parts for validation Multiple

Prototype Control Plan Inspection plan for prototypes Quality

Special Characteristics (Updated) CC/SC finalized Quality

Gate 2 Criteria:

• DFMEA complete (RPN addressed)

• Design reviews completed

• Drawings released

• Prototypes built and validated

• Design verification results acceptable

• Special characteristics agreed with customer

Note: For contract manufacturing (MNMUK), Phase 2 is often customer-led. Focus on DFM feedback and prototype support.

Phase 3: Process Design and Development

Purpose: Develop manufacturing process

Key Deliverables:

Deliverable Description Owner

Process Flow Diagram All operations mapped Mfg Eng

Floor Plan Layout Equipment and flow layout Mfg Eng

Characteristics Matrix Link characteristics to operations Quality

PFMEA Process Failure Mode Effects Analysis Quality/Mfg Eng

Pre-Launch Control Plan Enhanced control for validation Quality

Process Instructions Operator work instructions Mfg Eng

MSA Plan Measurement system analysis plan Quality

Preliminary Process Capability Plan Cpk study plan Quality

Packaging Standards Pack spec developed Logistics

Management Support (Updated) Confirm resources GM

Gate 3 Criteria:

• Process flow complete and approved

• PFMEA complete (high RPNs addressed)

• Pre-launch control plan approved

• Work instructions drafted

• MSA plan established

• Tooling/equipment ordered or available

• Packaging spec approved

Phase 4: Product and Process Validation

Purpose: Validate manufacturing process

Key Deliverables:

Deliverable Description Owner

Significant Production Run PPAP quantity produced Production

MSA Results Gage R&R complete Quality

Preliminary Process Capability Initial Cpk/Ppk studies Quality

Production Part Approval PPAP package complete Quality

Production Validation Testing Performance testing Quality

Production Control Plan Final control plan Quality

Quality Planning Sign-Off Team approval Cross-functional

PSW Part Submission Warrant Quality

Gate 4 Criteria:

• Significant production run complete

• MSA acceptable (<10% GR&R for CC, <30% for SC)

• Process capability acceptable (Ppk ≥1.67 for CC, ≥1.33 for SC)

• PPAP package complete per customer level

• Customer approval (PSW signed)

• Production control plan implemented

• Operators trained

Phase 5: Feedback, Assessment and Corrective Action

Purpose: Continuous improvement during production

Key Activities:

Activity Description Frequency

Variation Reduction Reduce process variability Ongoing

Customer Satisfaction Monitor complaints, returns Monthly

Delivery Performance OTD tracking Weekly

Lessons Learned Capture and share Per program

Control Plan Updates Based on experience As needed

PFMEA Updates Based on field issues As needed

Ongoing Requirements:

• Customer complaints tracked and resolved

• Process capability maintained

• Control plans current

• Lessons learned documented

• Continuous improvement projects active

PPAP Submission Levels

Level Requirements When Used

Level 1 PSW and Appearance Approval Report only Customer trusts supplier

Level 2 PSW with product samples and limited data Reduced documentation

Level 3 PSW with product samples and complete data Default

Level 4 PSW with complete data (no samples) Customer-specific

Level 5 PSW with product samples and complete data at supplier site Customer review on-site

MNMUK Default: Level 3 unless customer specifies otherwise.

PPAP 18 Elements

Element Checklist

Element Level 1 Level 2 Level 3 Level 4 Level 5 Owner

1 Design Records R S S * R Engineering

2 Authorized Engineering Change Documents R S S * R Engineering

3 Customer Engineering Approval R R S * R Commercial

4 Design FMEA R R S * R Engineering

5 Process Flow Diagram R R S * R Mfg Eng

6 Process FMEA R R S * R Quality

7 Control Plan R R S * R Quality

8 Measurement System Analysis R R S * R Quality

9 Dimensional Results R S S * R Quality

10 Material, Performance Test Results R S S * R Quality

11 Initial Process Studies R R S * R Quality

12 Qualified Laboratory Documentation R S S * R Quality

13 Appearance Approval Report (AAR) S S S * R Quality

14 Sample Production Parts R S S R R Quality

15 Master Sample R R S * R Quality

16 Checking Aids R R S * R Quality

17 Customer-Specific Requirements R R S * R Quality

18 Part Submission Warrant (PSW) S S S S S Quality

Legend: S = Submit to customer | R = Retain at supplier | * = Retain and submit on request

Element Details

Element 1: Design Records

• Released engineering drawings

• CAD data if applicable

• Current revision level

• All engineering specifications referenced

Element 2: Authorized Engineering Change Documents

• ECNs (Engineering Change Notices)

• Deviations approved by customer

• Temporary deviations with expiry dates

Element 3: Customer Engineering Approval

• Evidence of customer approval for design

• Typically for proprietary designs

• Not required if customer-owned design

Element 4: Design FMEA (DFMEA)

• Covers design failure modes

• Often customer responsibility for contract manufacturing

• MNMUK may not have access if design is proprietary

Element 5: Process Flow Diagram

• All operations including rework/inspection

• Material flow indicated

• Must match Control Plan operations

Element 6: Process FMEA (PFMEA)

• All process failure modes

• Current controls documented

• RPN/AP action items closed

• Special characteristics identified

• Reference: Load Pfmea skill

Element 7: Control Plan

• Matches PFMEA and process flow

• All special characteristics controlled

• Appropriate sample sizes and frequencies

• Reaction plans defined

• Reference: Load Controlplan skill

Element 8: Measurement System Analysis (MSA)

• Gage R&R for all variable gages

• Attribute agreement for attribute checks

• Acceptance: <10% for CC, <30% for SC

• Reference: Load Msa skill

Element 9: Dimensional Results

• All drawing dimensions measured

• Sample size typically n=3-5 parts

• Include layout inspection report

• Mark CC/SC results

Element 10: Material, Performance Test Results

• Material certifications

• Performance test results (DVP&R)

• Third-party test reports if required

• Traceability to material lots

Element 11: Initial Process Studies

• Capability studies (Ppk/Cpk)

• Minimum 30 parts, 300 readings for SPC

• Acceptance: Ppk ≥1.67 (CC), ≥1.33 (SC)

• Reference: Load Spc skill

Element 12: Qualified Laboratory Documentation

• Scope of lab accreditation

• ISO/IEC 17025 scope if applicable

• Third-party lab certifications

Element 13: Appearance Approval Report (AAR)

• Required for appearance items only

• Color, grain, texture approval

• Customer-signed AAR form

Element 14: Sample Production Parts

• Parts from significant production run

• Quantity per customer requirement (typically 3-10)

• Representative of normal production

Element 15: Master Sample

• Retained production sample

• Same as submitted samples

• Stored per retention requirements

Element 16: Checking Aids

• Custom gages, fixtures, templates

• Calibrated and identified

• Match Control Plan references

Element 17: Customer-Specific Requirements

• OEM-specific PPAP requirements

• May include additional forms/checklists

• Check customer portal/manual

Element 18: Part Submission Warrant (PSW)

• Summary of PPAP submission

• Weight, material declaration

• Customer-specific markings

• Authorized signatures

PSW Generation Guide

Required Information

Part Submission Warrant

Part Information

Supplier Information

Submission Details

Weight Declaration

Material Information

Special Characteristics

Submission Checklist

• All required elements per submission level included
• Capability requirements met
• No open issues or deviations
• Customer-specific requirements addressed

Disposition (Customer Use)

[ ] Approved [ ] Interim Approval (expiry: _______) [ ] Rejected (reason: _______)

Authorization

Timing Plan Elements

Standard Milestones

Milestone APQP Phase Typical Timing

Program Kick-Off 1 T-24 weeks

Design Release 2 T-18 weeks

Tooling Order 2 T-16 weeks

Process Design Complete 3 T-12 weeks

Tooling Receive 3 T-10 weeks

First Article 3 T-8 weeks

PPAP Run 4 T-6 weeks

PPAP Submission 4 T-4 weeks

Customer Approval 4 T-2 weeks

SOP (Start of Production) 5 T-0

MNMUK Program Phases

Phase Duration Key Activities

Quotation 1-2 weeks RFQ response, feasibility

Award 1 week PO receipt, kick-off

Planning 2-3 weeks APQP plan, team formation

Development 4-8 weeks Process design, tooling

Validation 2-4 weeks PPAP run, capability

Approval 1-2 weeks PPAP submission, PSW

Launch 1-2 weeks Production ramp-up

Open Issues Management

Issue Categories

Category Description Example

Design Drawing/specification issues GD&T clarification needed

Process Manufacturing capability Cpk below target

Tooling Equipment/fixture issues Tool modification required

Quality Inspection/testing gaps MSA fail, need new gage

Supply Material/supplier issues Long lead material

Commercial Contract/pricing issues Scope change

Issue Status

Status Definition Action

Open Issue identified, not resolved Assign owner, target date

In Progress Work underway Track to completion

Pending Waiting on external input Follow up required

Closed Issue resolved Document resolution

Escalated Risk to timing/quality Management attention

Issue Tracking Format

Open Issues Log

Phase Gate Review Meeting

Agenda Format

Program Status (5 min)

• Timeline status (Green/Yellow/Red)

• Budget status

• Customer communication

Deliverable Review (20 min)

• Checklist walkthrough

• Evidence of completion

• Identify gaps

Risk Review (10 min)

• Open issues summary

• Top 3 risks

• Mitigation status

Gate Decision (5 min)

• Pass / Conditional Pass / Fail

• Actions if conditional

• Next gate schedule

Gate Decision Criteria

Decision Criteria Action

Pass All deliverables complete, no critical issues Proceed to next phase

Conditional Pass Minor items open, clear path to close Proceed with tracking

Fail Critical items incomplete, significant risk Hold, develop recovery plan

IATF 16949 Alignment

APQP/PPAP is a core requirement of IATF 16949 (Clause 8.3 - Design and Development).

MNMUK IATF 16949 Context

Certification Target: November 2027 Current Status: ISO 9001 Certified, upgrading to IATF 16949

Reference Documentation:

• Compliance Plan: ~/projects/work/docs/compliance/IATF16949_Compliance_Plan.md

• Quality Manual: ~/projects/work/docs/work-instructions/QM-001_Quality_Manual.md

IATF Requirements Addressed by This Skill

IATF Clause Requirement APQP/PPAP Coverage

8.3.2.1 Design and development planning (APQP) Full 5-phase APQP

8.3.3.1 Product design inputs Phase 1 & 2 deliverables

8.3.3.2 Manufacturing process design inputs Phase 3 deliverables

8.3.4.1 Design outputs (DFMEA, Control Plan) Phase 2-4 outputs

8.3.5.2 Manufacturing process validation Phase 4 validation

8.3.6.1 Design and development changes Re-submission triggers

9.1.1.1 Process capability monitoring PPAP Element 11

Capability Requirements (per QM-001)

Characteristic Ppk Minimum Notes

Critical (CC) ≥1.67 Safety/regulatory impact

Significant (SC) ≥1.33 Fit/function impact

Standard ≥1.00 All other characteristics

PMO Governance

APQP programs at MNMUK are managed through the Programme Management Office (PMO):

• Monthly IATF Steering Committee reviews program status

• Phase gate reviews align with IATF documentation requirements

• Lessons learned feed into quality system continuous improvement

Integration with Related Skills

PFMEA

PFMEA is PPAP Element 6:

• Required for all PPAP levels

• Must be complete before Gate 3

• High RPN items must be addressed

Load: read ~/.claude/skills/Pfmea/SKILL.md

Control Plan

Control Plan is PPAP Element 7:

• Pre-launch for Gate 3

• Production for Gate 4

• Must align with PFMEA

Load: read ~/.claude/skills/Controlplan/SKILL.md

MSA

MSA is PPAP Element 8:

• Plan at Gate 3

• Results at Gate 4

• All gages must pass

Load: read ~/.claude/skills/Msa/SKILL.md

SPC

Initial process studies are PPAP Element 11:

• Capability studies at Gate 4

• Cpk/Ppk targets must be met

Load: read ~/.claude/skills/Spc/SKILL.md

Internal Audit

APQP program audit requirements:

• Phase gate reviews documented

• PPAP records auditable

• Process effectiveness verified

Load: read ~/.claude/skills/Internalaudit/SKILL.md

Examples

Example 1: Check PPAP readiness

User: "What PPAP elements do I need for Level 3?" → Lists all 18 elements with Submit/Retain status → Highlights elements to submit → Notes MNMUK-specific considerations

Example 2: Run phase gate review

User: "Run Gate 3 checklist for the XYZ project" → Loads PhaseGate workflow → Walks through Phase 3 deliverables → Identifies gaps and assigns actions

Example 3: Generate PSW

User: "Create a PSW for part 12345" → Collects required information → Generates PSW document → Includes all declarations and checklists

Example 4: Track program timing

User: "What's the timeline for our new damper launch?" → Loads TimingPlan workflow → Creates milestone schedule → Identifies critical path items

Supplementary Resources

For detailed guidance: read ~/.claude/skills/Apqpppap/CLAUDE.md

For templates: ls ~/.claude/skills/Apqpppap/templates/

For phase gate checklists: read ~/.claude/skills/Apqpppap/reference/gate-checklists.md

For PPAP element forms: read ~/.claude/skills/Apqpppap/reference/ppap-forms.md