AS9145 APQP and PPAP Checklist (Free, PDF)

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10 critical items still open - these are the highest-risk gaps.

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Plan and define

Customer requirement for AS9145 is confirmed in the contract and the submission level is knownCRITICALA cross-functional APQP team with a named leader is establishedA project plan with milestones, owners and customer review gates existsDesign inputs, key characteristics and special requirements are identifiedCRITICALRisks and opportunities are assessed for the programCustomer and regulatory requirements, including counterfeit prevention, are flowed to the team

Product and process design

Design records and drawings are the current released revisionCRITICALProcess flow diagram covers every operation, inspection and special processDesign FMEA is available from the design authority if applicableProcess FMEA is complete, links to key characteristics and has actions with ownersCRITICALControl plan defines methods, sample sizes, frequencies and reaction plansCRITICALTooling, gages and fixtures are designed, qualified and calibratedSpecial process suppliers are approved (for example Nadcap where required)

Process validation

Production trial run is done with production tooling, people and environmentMeasurement system analysis is completed for key gagesCRITICALInitial process capability studies are done for key characteristicsCRITICALFirst article inspection per AS9102 is complete and acceptedPackaging, labeling and preservation requirements are verifiedCapacity and takt are demonstrated at the quoted rate

PPAP submission package

Part submission warrant is completed and signed by an authorized personCRITICALDesign records, engineering change documents and approvals are includedDimensional results and ballooned drawing are includedMaterial, special process and functional test results are included with certificatesRecords of compliance with customer-specific requirements are includedSample parts and master samples are prepared if requestedSubmission is sent at the required level and recorded with a date

Supply chain and launch

Sub-tier suppliers on critical items are flowed down APQP and PPAP requirementsCRITICALSub-tier approvals or submissions are collected before your own submissionProduction control plan is released to the floor and routings reference itOperators are trained on key characteristics and reaction plansCustomer approval or interim approval status is tracked and communicated

Post-launch and change management

Lessons learned are captured and fed into the next programChanges to process, source or tooling trigger a PPAP or FAI reviewCRITICALControl plan and PFMEA are updated after escapes or customer feedbackPPAP records are retained for the period required by the contract

Score is the share of items complete. AS9145 requires APQP and PPAP when the customer specifies it, and customer-specific submission levels and evidence apply. Critical items are the ones most often rejected.

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How to use the checklist

Run it at program kickoff and again before the PPAP submission. Mark items complete only when the evidence exists and is current. Use the critical flag to find the items most likely to cause a rejection: unlinked FMEA and control plan, no MSA, missing capability data, uncontrolled sub-tier suppliers. Export the result as the status record for the program review.

Confirm submission level with the customer before starting
Link FMEA, control plan and drawing characteristics by ID
Collect sub-tier evidence early because it has the longest lead time
Review with the quality lead before submission

What AS9145 covers

AS9145 defines requirements for advanced product quality planning and the production part approval process in aerospace, and it builds on the earlier practices from automotive and the AS9100 series. It works alongside AS9102 for first article inspection and AS9103 for key characteristics. The customer decides when it applies, which elements are required and at what level of submission, so always check the contract.

How the pieces fit

APQP is the planning flow. PPAP is the evidence package that shows the plan worked. In practice the FMEA identifies risks, the control plan assigns controls, MSA and capability studies show the controls are good enough, and the FAI proves the part meets the drawing. If one link is missing, the package becomes hard to defend in review.

Common mistakes

Frequent causes of rejection are a control plan that does not match the actual process, capability data from too few parts, gages that were not studied and forgotten sub-tier flow-down. In an ERP, hold the routing, control plan reference and inspection plan under one engineering change process so a change cannot go live without the associated PPAP review.

Frequently Asked Questions

Is AS9145 mandatory?

It is mandatory only when a customer or contract requires it. Many aerospace primes and tier-one suppliers flow it down. If you are unsure, check the purchase order, the quality clauses and the supplier handbook, and ask the customer which submission level applies.

How is AS9145 PPAP different from AS9102 FAI?

FAI proves a specific part meets all drawing requirements. PPAP is a broader package showing the whole process, including FMEA, control plan, capability and supplier controls, can produce conforming parts at rate. A PPAP package normally includes the FAI as one of its elements.

When do I need to resubmit PPAP?

Typically after significant changes to design, process, tooling, location or sub-tier source, or after a long production lapse, and when the customer requires it. Your contract defines the triggers. Document each change and agree with the customer on whether resubmission is needed.

Do I need MSA for every gage?

Focus on gages used for key characteristics and critical features. Study them for repeatability and reproducibility, and for attribute gages use an attribute agreement study. Document the method and acceptance criteria used so a reviewer can follow it.

If your control plans, routings and inspection plans drift apart, we can help tie them together in your ERP and MES.

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AS9145 APQP and PPAP Checklist for Aerospace Suppliers