PPAP Dimensional Results Worksheet
Dimensional results are element 9 of PPAP. Every characteristic on the ballooned drawing must be measured on production parts, with actual values recorded against the tolerance. This worksheet records five measurements per characteristic and checks conformance for you.
| Char. no. | Characteristic | Nominal | Lower limit | Upper limit | Sample 1 | Sample 2 | Sample 3 | Sample 4 | Sample 5 | Average | Lowest | Highest | Within limits (1 = yes) | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
120.02 | 119.95 | 120.11 | 1 | |||||||||||
10.014 | 10 | 10.03 | 1 | |||||||||||
35.006 | 34.97 | 35.04 | 1 | |||||||||||
4.05 | 4.02 | 4.11 | 0 | |||||||||||
90.1 | 89.8 | 90.4 | 1 |
Use one row per ballooned characteristic and add rows until the whole drawing is covered. Many customers require measurements on a set number of pieces from different cavities or lines; extend the sample columns outside this sheet if needed. A zero in the last column flags a characteristic that needs investigation.
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How to use it
Number each characteristic to match the ballooned drawing. Enter nominal and limits exactly as printed, including any unilateral tolerances. Enter measurements from parts built with production tooling, process and gauges, ideally spread across cavities, fixtures or lines. The sheet calculates average, lowest and highest per row, then flags whether all samples sit within limits. Export to Excel for the PPAP package.
What good looks like
Every row should show 1 in the last column. In the example, the flange thickness has one sample at 4.11, above the 4.10 limit, so that row fails. That is exactly the kind of finding to resolve before warrant submission: adjust the process, confirm the measurement, or request a deviation. Attach capability studies for special characteristics, since a result that passes on five parts does not prove the process is capable.
- One row per ballooned characteristic
- Values from production tooling and process
- Units consistent with the drawing
- Failed rows investigated before submission
Measurement quality
Results are only as reliable as the gauge. Use calibrated equipment appropriate for the tolerance, with gauge repeatability and reproducibility studies on key characteristics. Record the gauge or CMM program ID in a separate column when the customer requires it. Take care with datum alignment on position characteristics, because a wrong setup can create false failures or false passes.
Common mistakes
Missing characteristics, such as notes and reference dimensions that carry tolerances, mixing units, reporting average only, and measuring prototype parts. Another common error is to round away the failure, for example showing 4.11 as 4.1. Report the resolution the gauge supports, and keep raw data available in the PPAP file.
Frequently Asked Questions
How many parts must be measured for PPAP dimensional results?
It depends on the customer. Many ask for at least a handful of parts per cavity, line or tool, and some require thirty or more for capability. Check the customer specific requirements, and measure more when multiple cavities are present.
Do I measure every dimension on the drawing?
Yes, every characteristic in the design record, including notes and reference items with tolerances, unless the customer says otherwise. Each should be ballooned and cross referenced to the dimensional results and the control plan.
What if a measurement is out of tolerance?
Do not submit it as a pass. Fix the process, confirm the measurement, or ask the customer for a deviation or interim approval with a corrective action plan. Disclose it on the warrant explanation field.
Does the worksheet calculate capability?
No. It checks conformance for five samples per row. Capability studies, such as Ppk or Cpk, require many more samples and are submitted as initial process studies, element 11 of PPAP.
Netray can discuss a private workflow that reads CMM or inspection exports and drafts the dimensional layout for engineer review.
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