PPAP Process Flow Diagram Template
The process flow diagram is PPAP element 4 and the first document in the quality chain, followed by the PFMEA and control plan. It shows every step from receiving to shipping so reviewers can see where risks and controls sit. This template builds a clean header and operation table you can export.
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PPAP Process Flow Diagram Template
Process Flow Diagram
Supplier: Acme Precision Components Ltd Part number: HSG-48213 Revision: C Part name: Pump housing Customer: Example Automotive Tier 1 Date: 2026-10-20 Prepared by: A. Singh, Process Engineer
Scope
This flow covers the process from: Receiving of aluminium bar stock to: Shipping to customer.
Symbols used: O = operation, I = inspection, S = storage, T = transport, R = rework or repair loop.
Operations
| Op no. | Type | Description | Machine / equipment | Characteristic or control point | Rework loop |
|---|---|---|---|---|---|
| 10 | O / I | Receive and inspect bar stock | Dock, certificate review | Material cert, lot ID | Reject to supplier |
| 20 | O | CNC turn | Lathe 4 | Bore diameter | Rework if oversize allowed |
| 30 | O | Deburr | Deburr cell | Cross hole burr | Re-deburr |
| 40 | O / I | Wash and dry | Wash line | Residual particles | Rewash |
| 50 | I | Final inspection and pack | Pack station | Labels, count | Re-pack |
| 60 | T | Ship to customer | Dock | Packing slip | None |
Sub-process and outsourced steps
List any outsourced operation (heat treat, plating, coating) with the sub-supplier name and approval status:
1. 2.
Approvals
Edit the operation table in the exported file to match your actual process. Operation numbers should match the PFMEA and control plan. The format is a generic starting point, not a customer-mandated form.
Want your routing compared to your PPAP flow?
Optional review of ERP routings against PPAP process flow documents.
Optional. The tool and every export work without this. No spam.
How to use the template
Fill in the header fields, then adjust the operation table in the exported file for your real steps. Include all value-adding steps, inspections, storage, transport, rework loops and outsourced operations. The flow must cover the whole process, including steps at sub-suppliers that affect the product. Number operations in a way you can keep stable, because the PFMEA and control plan will reference them.
- Start at receiving and end at shipping
- Show rework and scrap paths explicitly
- Include outsourced steps and the sub-supplier
- Keep operation numbers identical across documents
What reviewers look for
Reviewers check that the flow matches the actual floor, not an idealised version. They compare it against the PFMEA and control plan to see that every operation appears in all three. Missing inspection points, undocumented rework and unlisted outsourced processing are the usual gaps. A well-drawn flow also shows material handling steps where mix-up or damage can occur.
Reading the sample flow
The sample shows a machined housing: receive and inspect bar stock, turn, deburr, wash, inspect and pack, then ship. Each row has a type code and a characteristic or control point so the risk steps can be traced into the PFMEA. Rework loops are listed so the reader knows which operations can send product back. Replace the sample rows with your own routing.
Common mistakes and ERP notes
The usual mistakes are copying the flow from another part number, leaving out the rework loop, and forgetting outsourced steps. If your ERP routing is accurate, use it as the starting point and keep operation numbers aligned. A mismatch between routing and flow diagram often reveals undocumented work centres or steps that operators perform off-system.
Frequently Asked Questions
Does the flow have to be a picture?
No. PPAP requires a process flow diagram, and many customers accept a table or flowchart as long as it shows all steps in sequence. Use the format the customer's specific requirements ask for, which may be a drawn flowchart.
Should I include inspection steps?
Yes. Show inspections, tests and holds, along with operations, so reviewers can see where product is checked. Include rework and scrap paths and mark where product is segregated.
How detailed should operations be?
Detailed enough that each step maps to a PFMEA row and control plan line. Avoid combining unrelated work into one box, but do not describe every motion. The operation level of your routing is usually right.
Can I export to Word?
Yes. Download the template as a Word, PDF or Excel file and replace the sample table rows with your own flow.
If your routing in the ERP is the real source of operation numbers, Netray can help compare it against your PPAP documents with read-only access.
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