The PPAP Elements That Matter for Castings
The AIAG PPAP manual lists 18 elements, and the submission level (commonly Level 3 for new parts) determines what you send versus keep on file. For castings the elements that cause the most work are the process flow and PFMEA covering melt, pour or shot, trim, machining and finishing; the control plan with reaction plans; dimensional results on the specified sample size from the production tooling; material certification and mechanical test results; and capability studies on critical characteristics. Leak test or pressure test data and X-ray results are frequently added through customer-specific requirements.
- Process flow and PFMEA tied to the actual casting route
- Control plan with frequency, method and reaction plan
- Dimensional layout from production tooling, all cavities
- Material, chemistry, mechanical and NDT results
Multi-Cavity and Multi-Tool Complications
For multi-cavity dies, customers usually expect dimensional results per cavity, which multiplies the inspection workload and makes cavity identification on each casting important. If a part is produced on more than one die or pattern, each tool may need its own submission. When you change a die, repair significantly or make an engineering change, a resubmission may be required depending on the customer's requirements.
Keep a clear link between part revision, tool number, cavity and the PPAP record, or you will not know later which submission covers which tooling.
Capability Studies and Gauge Studies
Customers commonly ask for process capability indices such as Cpk or Ppk on critical characteristics and measurement system analysis (gauge R and R) on the gauges used. Die casting variation changes with die temperature, wear and shot parameters, so initial capability may differ from long-term. Plan the initial study on stabilized production, not first shots.
Keep the raw data in a form that can be re-queried. An SPC system or ERP quality module that stores characteristic measurements by lot, die and cavity makes this much easier than scanning paper layouts.
- Define critical characteristics and measurement method early
- Run capability on stable production samples
- Record cavity and die identification for each measurement
- Store MSA results with the gauge calibration record
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Keeping PPAP Evidence Audit Ready
PPAP is not a one-time packet. IATF audits and customer visits ask for current control plans, evidence that you follow them, and records of changes. Maintain a controlled folder per part number with revision history, tool linkage, approvals and dates, and review it when you change process, tooling, supplier or location.
Document control matters here: out-of-date control plans on the floor are a common audit finding. If PPAP evidence lives across shared drives, email attachments and paper binders, a private search layer can help you find the current approved version and the supporting data fast, but it needs a clean controlled source to point at.
When Full PPAP Is Not Required
Not every customer requires PPAP. Industrial, energy and general-purpose buyers may accept a first article inspection report, certificates and a control plan. Do not build automotive-grade documentation for customers who do not ask for it, but also do not wait to be asked if you are targeting automotive.
Read the supplier quality manual and purchase order terms to confirm the required submission level before you quote the cost of compliance.
Frequently asked questions
What is PPAP in die casting?
It is a documented approval package showing that your process can consistently produce parts meeting customer requirements at production rate. It typically includes process flow, PFMEA, control plan, dimensional results, material and test results, capability studies and a submission warrant.
What PPAP level do I need?
The customer decides, and it is stated in their supplier quality manual or the purchase order. Level 3 is common for new parts, with full supporting data submitted, but some customers use other levels or custom requirements.
Do I need PPAP for each cavity?
Many customers expect dimensional results from every cavity of a multi-cavity die, with cavity identification on the parts. Confirm in the customer requirements because practices vary.
How often must PPAP be resubmitted?
Typically for significant changes such as tooling changes or major repair, process changes, material source changes or customer-specified triggers. Check your customer's requirements and notify them of changes as required.
If PPAP evidence is spread across shared drives and binders, we can help you build a private, searchable index of your current approved records with links to the source files.