PPAP Package Example (Completed Sample, Element by Element, with Blank Forms)
This PPAP package example shows what a completed submission looks like for a machined part: the 18 elements as an index, a summary Part Submission Warrant, dimensional results, MSA and process capability notes. Change the fields to your part and export to Word or PDF to use as a starting layout.
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PPAP Package Example (Completed Sample Walkthrough)
PPAP Submission Cover Sheet and Index
Supplier: Acme Precision Components Ltd (S-40217) Customer: Example Automotive Systems Part: 55021-7788, Hydraulic valve body Drawing: Rev D, 2026-05-12 Submission level: Level 3 Reason: Initial submission Submission date: 2026-10-20 Contact: M. Patel, Supplier Quality Engineer
Element checklist (what is in this sample package)
| No. | Element | Status in this example | Sample content |
|---|---|---|---|
| 1 | Design records (ballooned drawing) | Included | Drawing Rev D, 2026-05-12 with all characteristics numbered |
| 2 | Engineering change documents | N/A | No change authorised in this run |
| 3 | Customer engineering approval | N/A | Not required for initial run |
| 4 | Design FMEA | Customer owned | Referenced if supplier is design responsible |
| 5 | Process flow diagram | Included | Receiving through shipping, 8 steps |
| 6 | Process FMEA | Included | Rows traced to control plan |
| 7 | Control plan | Included | Production phase, special characteristics marked |
| 8 | MSA studies | Included | Bore gauge GR&R 7.4% of tolerance, ndc 14 |
| 9 | Dimensional results | Included | 5 pieces, all characteristics, from the production run |
| 10 | Material and performance test results | Included | Ductile iron EN-GJS-500-7, mill certificate 3.1 attached |
| 11 | Initial process studies | Included | Ppk 1.82 on bore diameter, 125 parts |
| 12 | Qualified laboratory documentation | Included | Lab scope and accreditation copy |
| 13 | Appearance approval report | N/A | No appearance requirement |
| 14 | Sample product | Per customer request | Retained samples labeled |
| 15 | Master sample | Retained | Kept at supplier |
| 16 | Checking aids | Listed | Go/no-go gauges with calibration records |
| 17 | Customer-specific requirements | Included | Checklist of requirements met |
| 18 | Part Submission Warrant (PSW) | Signed | Below |
Part Submission Warrant (summary of fields)
Part name and number: Hydraulic valve body, 55021-7788 Supplier and code: Acme Precision Components Ltd, S-40217 Reason for submission: Initial submission Submission level: Level 3 Run at rate: 300 pieces from a significant production run using production tooling, gauges, process and operators Declaration: the samples represent parts made during a significant production run and all results meet the design record and customer requirements. Any deviation is listed. Disposition requested from customer: approved, interim approval, or rejected.
Dimensional results (excerpt)
| Char no. | Requirement | Sample 1 | Sample 2 | Sample 3 | Sample 4 | Sample 5 | Result |
|---|---|---|---|---|---|---|---|
| 1 | Bore 18.000 +0.021 / 0 mm (special) | 18.009 | 18.011 | 18.008 | 18.012 | 18.010 | OK |
| 2 | Length 65.00 +/- 0.15 mm | 65.04 | 64.97 | 65.02 | 65.06 | 65.01 | OK |
| 3 | Port position 12.50 +/- 0.10 mm | 12.53 | 12.48 | 12.51 | 12.55 | 12.49 | OK |
Control plan and MSA notes
Control plan: the bore diameter is a special characteristic controlled with an air gauge, 5 parts per hour, X-bar and R chart, and the reaction plan stops the machine and contains parts back to the last good check.
MSA: Bore gauge GR&R 7.4% of tolerance, ndc 14. Studies are done on the gauge named on the control plan, using 10 parts, 3 operators and 3 trials, with calibration traceable to national standards. Attribute checks, such as visual or go/no-go gauges, use an attribute agreement analysis.
Authorisation
This is a fictional sample to show structure. It is not the AIAG PPAP form; the PSW summarizes its fields only. Always follow the PPAP manual edition and customer-specific requirements for your customer. Never submit invented data: results must come from the actual production run.
PPAP pre-submission review
Optional: we can review a package for revision and traceability gaps before you submit.
Optional. The tool and every export work without this. No spam.
How to fill PPAP documents
Start with the customer's requirement: the submission level and the elements they require. Level 3, the default, needs the warrant plus product samples and complete supporting data. Collect records from the real production run at production rate: the dimensional results come from measured parts, the capability study from a stable run, and the MSA from the gauges named in the control plan. Then assemble in the element order, number each page, write the warrant last, and have an authorised person sign it. Submit through the customer's portal, commonly Covisint or the customer's supplier system, or as agreed.
- Use the same part revision across the drawing, control plan, FMEA and results
- Every characteristic on the drawing needs a result
- Explain any N/A element in writing
- Do not submit before capability and MSA are acceptable
What a PPAP file and procedure should contain
A PPAP file is the full set of records per part number: the 18 elements, the signed warrant, the customer disposition and any change history. Your PPAP procedure should define who owns each element, how the team reviews the package before submission, how ERP and document control keep revisions aligned, and how you handle resubmission after a change. Keep the file for the life of the part plus the retention period the customer requires. Update it when anything listed in the manual as a trigger occurs, such as a tooling change, a new sub-supplier or a process change.
MSA and capability results in the example
The sample MSA reports GR&R of 7.4% of tolerance with 14 distinct categories. Under the AIAG MSA guidance, under 10% is generally acceptable, 10% to 30% may be accepted based on importance, and over 30% is not acceptable. The capability study shows Ppk 1.82 on the bore diameter over 125 parts, which clears the common 1.67 requirement for initial studies on special characteristics, though your customer sets the actual criterion. If a result falls short, do not submit: document a plan with 100% inspection and request an interim approval if the customer allows.
Common reasons PPAP submissions are rejected
Frequent causes are dimensional results from prototype parts rather than the production run, a ballooned drawing at the wrong revision, a control plan that does not match the PFMEA, missing customer-specific requirements, an unsigned or incomplete warrant, and gauges with no MSA. Review the package against the customer's checklist before sending it. A short internal pre-submission review saves weeks of resubmission and delays the production release you are trying to protect.
Frequently Asked Questions
How many parts are needed for a PPAP submission?
The manual calls for parts from a significant production run, normally one to eight hours or 300 consecutive pieces unless the customer says otherwise. Dimensional results typically cover at least a handful of parts, and capability studies use at least 100 pieces, or per customer requirement.
Which PPAP level should I submit?
Whichever the customer specifies. Level 3 is the default: warrant, samples and complete supporting data. Level 1 is the warrant only, Level 2 adds limited data, Level 4 is as defined by the customer and Level 5 requires review at the supplier site.
Is there an official AIAG PPAP template in Excel?
AIAG sells the PPAP manual and forms, and many customers publish their own templates. This page provides a layout based on the element structure, not a copy of the official forms.
Do I need a new PPAP after a change?
Often yes. Changes to design, tooling, process, material source or location usually require notification and, depending on the customer, a resubmission. Check customer-specific requirements before implementing the change.
If PPAP data lives across ERP, PLM and spreadsheets, Netray can build a private AI layer on your own servers that checks revision consistency before you submit.
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Guides
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