Meaning
Quality assurance protocol establishing that a supplier’s manufacturing process can consistently produce plastic parts meeting all engineering design and specification requirements during actual production runs. The approval process requires executing a standardized production run using machinery and cycle times to generate test samples and statistical data. Achieving PPAP qualification authorizes full-rate commercial production and shipment of moulded plastic components.
The protocol stops applying once full production sign-off is granted, unless resin supplier changes or facility relocations occur.
Document Submission
Documentation packages compile dimensional inspection results, material test reports, process flow diagrams, and failure mode analysis records. Submitting physical sample parts allows customer quality teams to verify cosmetic appearance and dimensional fit. Complete submission packages prove that the moulding process consistently meets design intent across multi-cavity tools.
Process Capability
Statistical studies calculate Cpk capability indices for critical dimensions across sample parts produced during the trial run. Process stability requires Cpk values exceeding one point three three, confirming low dimensional variance. Moulders adjust injection speed, hold pressure, and cooling times to achieve required statistical control.
Production Approval
Approval status grants authorization to ship production quantities to assembly plants. Level three submission requires full documentation plus sample parts, representing the standard requirement for automotive injection moulding. Operating without formal qualification exposes suppliers to part rejections and financial liabilities for non-conforming batches.