PPAP Course

Lesson 1 • PPAP Within the Supply Chain

Explains how PPAP connects suppliers, manufacturers, and customers in a quality assurance loop. Clarifies roles and responsibilities at each supply chain tier.

Lesson 2 • Submission Levels and Triggers

Defines the five PPAP submission levels and the conditions that trigger each. Students can select the correct level for a given scenario.

Lesson 3 • Key Terminology and Standards

Introduces essential vocabulary and the governing reference manual used throughout the course. Accurate terminology prevents miscommunication with customers and auditors.

Lesson 1 • Design Records and Drawings

Covers the types of design records accepted in a PPAP and how to verify their completeness. Connects drawing accuracy to downstream measurement and inspection activities.

Lesson 2 • Engineering Change Documentation

Explains how authorised engineering changes are captured and linked to the PPAP submission. Ensures traceability between design intent and produced parts.

Lesson 3 • Customer Engineering Approval

Details the process for obtaining formal customer sign-off on design deviations or new designs. Establishes the approval pathway before production tooling is committed.

Lesson 1 • PFMEA Alignment with Other PPAP Elements

Shows how PFMEA outputs feed directly into the control plan and measurement system analysis. Reinforces the interconnected nature of PPAP documentation.

Lesson 2 • Process Flow Diagram Development

Teaches construction of a process flow diagram that maps every manufacturing step from receiving to shipping. The diagram serves as the backbone for PFMEA and control plan alignment.

Lesson 3 • Severity, Occurrence, and Detection Ratings

Explains the rating scales for severity, occurrence, and detection and how to apply them consistently. Consistent ratings produce defensible risk priority numbers for customer review.

Lesson 4 • Recommended Actions and Follow-Up

Guides students through prioritising high-RPN items and documenting corrective actions with owners and due dates. Demonstrates how updated RPNs confirm risk reduction.

Lesson 1 • Control Methods and Reaction Plans

Covers selection of inspection methods, sample sizes, frequencies, and reaction plans for out-of-control conditions. Ensures operators have clear instructions when nonconformances occur.

Lesson 2 • Control Plan Format and Structure

Introduces the standard control plan header, column definitions, and three phases: prototype, pre-launch, and production. Students understand what each phase requires.

Lesson 3 • Control Plan Review and Approval

Explains the internal and customer approval process for control plans and how to manage revisions. Approved control plans become binding quality commitments.

Lesson 1 • Attribute MSA and Special Cases

Covers attribute agreement analysis for go/no-go gauges and visual inspection systems. Addresses MSA for destructive testing and short-run production scenarios.

Lesson 2 • Interpreting and Reporting MSA Results

Teaches acceptance criteria for %GRR, number of distinct categories, and bias studies. Students write a compliant MSA summary for inclusion in the PPAP package.

Lesson 3 • Gauge R&R Study Execution

Walks through the crossed gauge R&R study design, data collection protocol, and ANOVA analysis. Students conduct a complete study and generate a results report.

Lesson 1 • Appearance Approval Report

Explains the Appearance Approval Report process for colour, texture, and gloss characteristics. Covers submission requirements and customer sign-off procedures.

Lesson 2 • Material and Functional Test Results

Addresses collection and documentation of material certifications, chemical analysis, and functional test data. Links test results to drawing specifications and customer requirements.

Lesson 3 • Dimensional Inspection Planning

Explains how to plan dimensional inspection using the ballooned drawing and control plan. Proper planning ensures all characteristics are measured before submission.

Lesson 1 • Acceptance Criteria and Customer Requirements

Defines standard capability acceptance thresholds and explains how customer-specific requirements may differ. Students apply correct thresholds to their own process data.

Lesson 2 • Calculating Cp, Cpk, Pp, and Ppk

Teaches the formulas and calculation steps for Cp, Cpk, Pp, and Ppk using production data. Students distinguish between short-term and long-term capability measures.

Lesson 3 • Foundations of Process Capability

Introduces the concept of process capability and its relationship to specification limits and process variation. Establishes why capability data is central to PPAP approval.

Lesson 1 • Continuous Improvement After PPAP Approval

Connects approved PPAP baselines to ongoing process improvement activities and lessons-learned capture. Students use PPAP data to drive sustainable quality gains.

Lesson 2 • Maintaining PPAP Records Post-Approval

Covers record retention requirements, change notification obligations, and periodic PPAP review triggers. Ongoing compliance prevents unplanned resubmissions and audit findings.

Lesson 3 • Assembling the Complete PPAP Package

Explains how to organise all 18 potential PPAP elements into a coherent, indexed submission package. A well-organised package reduces customer review time and rejection risk.

Lesson 4 • Customer Review and Disposition Outcomes

Describes the three possible customer dispositions—full approval, interim approval, and rejection—and the supplier's obligations for each. Students draft response plans for non-full approvals.