PPAP Pre-Submission Review Checklist (Free)

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

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Package basics

Customer, part number and drawing revision are identical on every documentCRITICALSubmission level and reason for submission confirmed in writing with the customerCRITICALCustomer-specific requirements reviewed and each one has evidenceDocument index lists each element with page or file referenceEngineering change documents for any open changes are attachedCRITICALCustomer portal or format requirements for file names and uploads are met

Risk documents

Process flow operation numbers match PFMEA and control planCRITICALEvery special characteristic from the drawing appears in the PFMEA and control planCRITICALHigh severity items have recommended actions closed or justifiedDFMEA included or a statement that the customer owns designControl plan reaction plans and frequencies are specific, not genericControl plan format and phase (prototype, pre-launch, production) match the customer's request

Measurement and capability

Every gauge in the control plan has a current calibration recordCRITICALGauge R&R or attribute study done for gauges on special characteristicsCRITICALDimensional results cover every ballooned dimension on the drawingCRITICALMeasured parts came from production tooling and process, with cavity or fixture identifiedInitial process studies use the required number of readings and show a stable processPpk or Cpk meets the customer minimum, or an action plan is agreed

Material and testing

Material certificates match the specification and lot used for the sample partsPerformance test results meet the drawing and referenced standardsLaboratory scope of accreditation covers the test methods usedAppearance approval report completed where appearance items applySubcontractor and supplier PPAP approvals are available for critical componentsCRITICAL

Samples and warrant

Sample parts are from the significant production run and correctly labelledMaster sample is signed, dated and storedPackaging and labelling meet the customer's standardWarrant data (weight, tooling, revision, rate) matches the packageCRITICALDeclaration signed by an authorised person after reviewing the whole packageCRITICALSecond person has reviewed the package against this checklist

Do not submit with any critical item open. A missed critical item is the most common route to rejection and a delayed launch.

Automate PPAP package tracking

An optional review of linking PPAP status to your ERP supplier and part data.

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How to use the checklist

Assign a reviewer who did not build the package. Work through each group, tick items that are true and verified in the documents, and leave the rest open. Critical items are those that most often cause rejection or compromise the declaration. Export the result as a record of internal review to keep in the project file.

Why consistency matters

A PPAP package is a set of linked documents. A change in drawing revision, an extra operation added to the flow, or a gauge swapped on the line affects several documents at once. Reviewers trace one characteristic from the drawing through the PFMEA, control plan, gauge, study and dimensional report. If the trace breaks, the package is usually returned.

Timing and approvals

Schedule the review at least a few days before the due date so there is time to correct findings. If a study cannot meet the target, contact the customer early and request interim approval with a corrective action plan, rather than waiting for a rejection. Record approvals and their conditions.

Common mistakes

Signing the warrant before the studies are complete, copying a previous part's control plan without edits, and using samples from a trial run instead of the significant production run are repeated findings. A short internal review catches most of them.

Frequently Asked Questions

Who should perform the pre-submission review?

Someone independent from the team that built the package, usually a quality engineer or supplier quality lead. A fresh reader is more likely to notice mismatched revisions, missing characteristics or blank fields.

What if the Ppk is below the customer minimum?

Tell the customer before submitting, share the data and propose a plan such as 100 percent inspection until capability improves. Many customers allow interim approval with conditions, but not without a plan.

Does this replace the customer's own requirements?

No. It supplements them. Customer-specific requirements and the assigned submission level always take priority, so add any customer items to your copy of the checklist.

How long should the review take?

For a typical single part package, a few hours with the documents in hand. Complex assemblies with many characteristics or subcomponents take longer, and are worth the time because a rejection delays launch.

If you want package status and part data pulled from your ERP automatically, we can help build a read-only report. Contact us with your system details.

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PPAP Pre-Submission Review Checklist