PPAP Checklist as per AIAG: 18 Elements + Bulk

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

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Step 1: Confirm what the customer requires

Submission level (1 to 5) confirmed in writing with the customer, not assumedCRITICALCustomer-specific requirements (CSR) for PPAP obtained and read, including portal or format rulesCRITICALPart is discrete (use the 18 elements) or bulk material (use the bulk checklist at the end)Reason for submission identified: new part, engineering change, tooling change, new source, process changeLatest drawing revision and any engineering change documents in hand

Step 2: Design and risk elements (1 to 7)

1. Design records: ballooned drawing and BOM, with all characteristics numberedCRITICAL2. Authorized engineering change documents for any change not yet on the drawing3. Customer engineering approval, if the customer requires it4. Design FMEA (design-responsible suppliers only) reviewed and signed5. Process flow diagram covers receiving through shipping and matches the control planCRITICAL6. Process FMEA covers every flow step, with severity, occurrence and detection ratings reviewedCRITICAL7. Control plan lists each characteristic, method, sample size, frequency and reaction planCRITICAL

Step 3: Measurement and results elements (8 to 12)

8. Measurement system analysis (gage R&R) done for every gage on the control planCRITICAL9. Dimensional results: every ballooned characteristic measured on production-representative partsCRITICAL10. Material and performance test results against the drawing and specification11. Initial process studies for special characteristics, with the capability index the customer requiresCRITICAL12. Qualified laboratory documentation (scope and accreditation for each lab used)

Step 4: Samples, aids and approvals (13 to 17)

13. Appearance approval report (AAR) if the part has appearance requirements14. Sample product delivered in the quantity and labeling the customer specified15. Master sample retained and tagged with part number, date and approval16. Checking aids listed, calibrated and covered by the revision control process17. Customer-specific requirements evidence attached (records, labels, portal entries)

Step 5: Warrant and submission (element 18)

18. Part Submission Warrant (PSW) completed with correct part number, revision, weight and reasonCRITICALAll data comes from a significant production run using production tooling, gages and rateCRITICALDocument package order and file names match the customer portal or submission instructionsInternal sign-off by quality, engineering and operations before sendingSubmission date and disposition tracked, with a plan for interim approval if needed

Bulk material variant (adhesives, sealants, chemicals, raw material)

Bulk material requirements checklist from the PPAP manual completed and signedCRITICALMaterial safety data sheet and any regulated substance declarations on fileCustomer-approved source and approved sub-suppliers listedMaterial and performance test results against the customer specificationCRITICALPart-based elements that do not apply (for example dimensional results, master sample) marked not applicable with the customer's agreementPackaging, labeling, shelf life and storage conditions agreedControl of the process that makes the batch (mix, cure, concentration) covered by the control plan

Every item ticked means you have the evidence in the package. Do not tick an item on the grounds that it is probably fine: the customer reviews the evidence, not the intention. Items marked critical cause most rejections. Always confirm the submission level and customer-specific requirements first, because they override this generic list.

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The five submission levels (the types of PPAP)

The level decides how much goes to the customer and how much you simply keep on file. Level 3 is the default when the customer says nothing. Confirm the level in writing because suppliers often prepare a full Level 3 package when Level 2 was enough, or the reverse.

Level 1: Part Submission Warrant only (plus an appearance approval report for appearance items).
Level 2: warrant with product samples and limited supporting data.
Level 3: warrant with product samples and complete supporting data.
Level 4: warrant plus whatever the customer defines.
Level 5: warrant with samples and complete data, reviewed at the supplier's site.

How to use this checklist

Start with step 1 so you know the level and customer rules. Then work through the design, measurement and approval elements in the order the manual presents them. Each critical item is one that commonly gets a submission rejected: a flow diagram that does not match the control plan, a gage with no R&R, capability studies on too few parts, or a warrant with the wrong revision. Whatever you do not submit at your level, you still retain and must produce on request.

Bulk material and common mistakes

Bulk materials such as adhesives, sealants and chemicals do not have dimensions, a master sample or appearance items, so the manual replaces part-based elements with a bulk material requirements checklist. The customer still expects the warrant, material and performance results and approved sources. The usual mistakes are submitting data from prototype tooling, skipping element 5 to 7 consistency, leaving gages without calibration status, and sending an old drawing revision on the warrant.

Data must come from a significant production run, normally about one to eight hours or 300 consecutive pieces unless the customer says otherwise.
The warrant, drawing, control plan and ballooned drawing must all show the same revision.
Special characteristics need the capability index the customer specifies, often 1.67 for initial studies.

Frequently Asked Questions

What is the AIAG PPAP checklist?

It is the list of 18 elements in the AIAG Production Part Approval Process manual that a supplier prepares to prove its process can make parts to the customer's requirements at the quoted rate. The elements run from design records to the Part Submission Warrant.

What are the types of PPAP?

In practice, the five submission levels: Level 1 warrant only, Level 2 warrant with samples and limited data, Level 3 warrant with samples and full data, Level 4 customer-defined, and Level 5 reviewed at the supplier's site. The bulk material variant is separate and applies to products such as chemicals.

Which PPAP elements apply to bulk material?

Bulk material uses the bulk material requirements checklist in place of several part-based elements, with the warrant, material and performance test results and approved sources still expected. Which elements are not applicable should be agreed with the customer rather than decided alone.

Which level should I submit if the customer does not say?

The manual treats Level 3 as the default, so prepare a complete package with samples. Better still, ask the customer to confirm the level in writing at quotation or program kickoff, as the extra work for an unneeded Level 3 is significant.

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PPAP Checklist as per AIAG: 18 Elements, Submission Levels and Bulk Material