APQP/PPAP - Advanced Product Quality Planning & Production Part Approval

When to Activate This Skill

"What APQP phase are we in?"
"Create a phase gate checklist"
"What PPAP elements are required?"
"Generate a PSW for [part]"
"Create a timing plan for [program]"
"Track open issues for [launch]"
"What's needed for PPAP Level [X]?"
"Run readiness review"

Workflow Routing

Workflow	Trigger	File
PhaseGate	"phase gate review", "gate checklist"	`Workflows/PhaseGate.md`
PpapPackage	"PPAP elements", "PPAP submission"	`Workflows/PpapPackage.md`
TimingPlan	"timing plan", "launch schedule"	`Workflows/TimingPlan.md`
OpenIssues	"open issues", "issue tracker"	`Workflows/OpenIssues.md`

APQP Five Phases

Phase 1: Plan and Define Program

Purpose: Determine customer needs and expectations

Key Deliverables:

Deliverable	Description	Owner
Voice of Customer	Customer requirements documented	Commercial
Business Plan	Program justification, capacity, investment	GM
Product/Process Assumptions	Initial feasibility assessment	Engineering
Product Assurance Plan	Quality objectives, reliability goals	Quality
Preliminary BOM	Initial bill of materials	Engineering
Preliminary Process Flow	High-level manufacturing concept	Mfg Eng
Preliminary Special Characteristics	Initial CC/SC identification	Quality
Management Support	Resource commitment	GM

Gate 1 Criteria:

Customer requirements documented and reviewed
Feasibility assessment complete
Resource plan approved
Risk assessment performed
Timing plan established

Phase 2: Product Design and Development

Purpose: Develop design to near-final form

Key Deliverables:

Deliverable	Description	Owner
DFMEA	Design Failure Mode Effects Analysis	Design Eng
Design for Manufacturability (DFM)	Manufacturing input to design	Mfg Eng
Design Verification Plan	DVP&R creation	Design Eng
Engineering Drawings	Released with GD&T	Design Eng
Engineering Specifications	Material, performance specs	Design Eng
Prototype Build	Sample parts for validation	Multiple
Prototype Control Plan	Inspection plan for prototypes	Quality
Special Characteristics (Updated)	CC/SC finalized	Quality

Gate 2 Criteria:

DFMEA complete (RPN addressed)
Design reviews completed
Drawings released
Prototypes built and validated
Design verification results acceptable
Special characteristics agreed with customer

Note: For contract manufacturing (MNMUK), Phase 2 is often customer-led. Focus on DFM feedback and prototype support.

Phase 3: Process Design and Development

Purpose: Develop manufacturing process

Key Deliverables:

Deliverable	Description	Owner
Process Flow Diagram	All operations mapped	Mfg Eng
Floor Plan Layout	Equipment and flow layout	Mfg Eng
Characteristics Matrix	Link characteristics to operations	Quality
PFMEA	Process Failure Mode Effects Analysis	Quality/Mfg Eng
Pre-Launch Control Plan	Enhanced control for validation	Quality
Process Instructions	Operator work instructions	Mfg Eng
MSA Plan	Measurement system analysis plan	Quality
Preliminary Process Capability Plan	Cpk study plan	Quality
Packaging Standards	Pack spec developed	Logistics
Management Support (Updated)	Confirm resources	GM

Gate 3 Criteria:

Process flow complete and approved
PFMEA complete (high RPNs addressed)
Pre-launch control plan approved
Work instructions drafted
MSA plan established
Tooling/equipment ordered or available
Packaging spec approved

Phase 4: Product and Process Validation

Purpose: Validate manufacturing process

Key Deliverables:

Deliverable	Description	Owner
Significant Production Run	PPAP quantity produced	Production
MSA Results	Gage R&R complete	Quality
Preliminary Process Capability	Initial Cpk/Ppk studies	Quality
Production Part Approval	PPAP package complete	Quality
Production Validation Testing	Performance testing	Quality
Production Control Plan	Final control plan	Quality
Quality Planning Sign-Off	Team approval	Cross-functional
PSW	Part Submission Warrant	Quality

Gate 4 Criteria:

Significant production run complete
MSA acceptable (<10% GR&R for CC, <30% for SC)
Process capability acceptable (Ppk ≥1.67 for CC, ≥1.33 for SC)
PPAP package complete per customer level
Customer approval (PSW signed)
Production control plan implemented
Operators trained

Phase 5: Feedback, Assessment and Corrective Action

Purpose: Continuous improvement during production

Key Activities:

Activity	Description	Frequency
Variation Reduction	Reduce process variability	Ongoing
Customer Satisfaction	Monitor complaints, returns	Monthly
Delivery Performance	OTD tracking	Weekly
Lessons Learned	Capture and share	Per program
Control Plan Updates	Based on experience	As needed
PFMEA Updates	Based on field issues	As needed

Ongoing Requirements:

Customer complaints tracked and resolved
Process capability maintained
Control plans current
Lessons learned documented
Continuous improvement projects active

PPAP Submission Levels

Level	Requirements	When Used
Level 1	PSW and Appearance Approval Report only	Customer trusts supplier
Level 2	PSW with product samples and limited data	Reduced documentation
Level 3	PSW with product samples and complete data	Default
Level 4	PSW with complete data (no samples)	Customer-specific
Level 5	PSW with product samples and complete data at supplier site	Customer review on-site

MNMUK Default: Level 3 unless customer specifies otherwise.

PPAP 18 Elements

Element Checklist

#	Element	Level 1	Level 2	Level 3	Level 4	Level 5	Owner
1	Design Records	R	S	S	*	R	Engineering
2	Authorized Engineering Change Documents	R	S	S	*	R	Engineering
3	Customer Engineering Approval	R	R	S	*	R	Commercial
4	Design FMEA	R	R	S	*	R	Engineering
5	Process Flow Diagram	R	R	S	*	R	Mfg Eng
6	Process FMEA	R	R	S	*	R	Quality
7	Control Plan	R	R	S	*	R	Quality
8	Measurement System Analysis	R	R	S	*	R	Quality
9	Dimensional Results	R	S	S	*	R	Quality
10	Material, Performance Test Results	R	S	S	*	R	Quality
11	Initial Process Studies	R	R	S	*	R	Quality
12	Qualified Laboratory Documentation	R	S	S	*	R	Quality
13	Appearance Approval Report (AAR)	S	S	S	*	R	Quality
14	Sample Production Parts	R	S	S	R	R	Quality
15	Master Sample	R	R	S	*	R	Quality
16	Checking Aids	R	R	S	*	R	Quality
17	Customer-Specific Requirements	R	R	S	*	R	Quality
18	Part Submission Warrant (PSW)	S	S	S	S	S	Quality

Legend: S = Submit to customer | R = Retain at supplier | * = Retain and submit on request

Element Details

Element 1: Design Records

Released engineering drawings
CAD data if applicable
Current revision level
All engineering specifications referenced

Element 2: Authorized Engineering Change Documents

ECNs (Engineering Change Notices)
Deviations approved by customer
Temporary deviations with expiry dates

Element 3: Customer Engineering Approval

Evidence of customer approval for design
Typically for proprietary designs
Not required if customer-owned design

Element 4: Design FMEA (DFMEA)

Covers design failure modes
Often customer responsibility for contract manufacturing
MNMUK may not have access if design is proprietary

Element 5: Process Flow Diagram

All operations including rework/inspection
Material flow indicated
Must match Control Plan operations

Element 6: Process FMEA (PFMEA)

All process failure modes
Current controls documented
RPN/AP action items closed
Special characteristics identified
Reference: Load Pfmea skill

Element 7: Control Plan

Matches PFMEA and process flow
All special characteristics controlled
Appropriate sample sizes and frequencies
Reaction plans defined
Reference: Load Controlplan skill

Element 8: Measurement System Analysis (MSA)

Gage R&R for all variable gages
Attribute agreement for attribute checks
Acceptance: <10% for CC, <30% for SC
Reference: Load Msa skill

Element 9: Dimensional Results

All drawing dimensions measured
Sample size typically n=3-5 parts
Include layout inspection report
Mark CC/SC results

Element 10: Material, Performance Test Results

Material certifications
Performance test results (DVP&R)
Third-party test reports if required
Traceability to material lots

Element 11: Initial Process Studies

Capability studies (Ppk/Cpk)
Minimum 30 parts, 300 readings for SPC
Acceptance: Ppk ≥1.67 (CC), ≥1.33 (SC)
Reference: Load Spc skill

Element 12: Qualified Laboratory Documentation

Scope of lab accreditation
ISO/IEC 17025 scope if applicable
Third-party lab certifications

Element 13: Appearance Approval Report (AAR)

Required for appearance items only
Color, grain, texture approval
Customer-signed AAR form

Element 14: Sample Production Parts

Parts from significant production run
Quantity per customer requirement (typically 3-10)
Representative of normal production

Element 15: Master Sample

Retained production sample
Same as submitted samples
Stored per retention requirements

Element 16: Checking Aids

Custom gages, fixtures, templates
Calibrated and identified
Match Control Plan references

Element 17: Customer-Specific Requirements

OEM-specific PPAP requirements
May include additional forms/checklists
Check customer portal/manual

Element 18: Part Submission Warrant (PSW)

Summary of PPAP submission
Weight, material declaration
Customer-specific markings
Authorized signatures

PSW Generation Guide

Required Information

# Part Submission Warrant

## Part Information
| Field | Value |
|-------|-------|
| Part Number | [Customer P/N] |
| Part Name | [Description] |
| Drawing Number | [Dwg #] |
| Drawing Rev | [Rev Level] |
| Customer | [Customer Name] |
| Buyer/Code | [Buyer Name/Code] |

## Supplier Information
| Field | Value |
|-------|-------|
| Supplier Name | Multimatic Niche Manufacturing UK |
| Supplier Code | [Customer-assigned code] |
| Address | [MNMUK Address] |
| Contact | [Quality Manager] |
| Phone/Email | [Contact details] |

## Submission Details
| Field | Value |
|-------|-------|
| PPAP Level | [1-5] |
| Submission Reason | [Initial, Change, Re-submission] |
| Engineering Change Level | [ECN #] |
| Purchase Order | [PO #] |

## Weight Declaration
| Measured | Specified | Difference |
|----------|-----------|------------|
| [Actual kg] | [Nominal kg] | [± kg] |

## Material Information
| Field | Value |
|-------|-------|
| Material | [Material spec] |
| Supplier | [Material supplier] |
| IMDS/MDS ID | [If required] |

## Special Characteristics
| Char | Drawing Ref | Result |
|------|-------------|--------|
| CC | [Zone/Ref] | PASS/FAIL |
| SC | [Zone/Ref] | PASS/FAIL |

## Submission Checklist
- [ ] All required elements per submission level included
- [ ] Capability requirements met
- [ ] No open issues or deviations
- [ ] Customer-specific requirements addressed

## Disposition (Customer Use)
[ ] Approved
[ ] Interim Approval (expiry: _______)
[ ] Rejected (reason: _______)

## Authorization
| Role | Signature | Date |
|------|-----------|------|
| Quality Manager | __________ | ________ |
| Customer Rep | __________ | ________ |

Timing Plan Elements

Standard Milestones

Milestone	APQP Phase	Typical Timing
Program Kick-Off	1	T-24 weeks
Design Release	2	T-18 weeks
Tooling Order	2	T-16 weeks
Process Design Complete	3	T-12 weeks
Tooling Receive	3	T-10 weeks
First Article	3	T-8 weeks
PPAP Run	4	T-6 weeks
PPAP Submission	4	T-4 weeks
Customer Approval	4	T-2 weeks
SOP (Start of Production)	5	T-0

MNMUK Program Phases

Phase	Duration	Key Activities
Quotation	1-2 weeks	RFQ response, feasibility
Award	1 week	PO receipt, kick-off
Planning	2-3 weeks	APQP plan, team formation
Development	4-8 weeks	Process design, tooling
Validation	2-4 weeks	PPAP run, capability
Approval	1-2 weeks	PPAP submission, PSW
Launch	1-2 weeks	Production ramp-up

Open Issues Management

Issue Categories

Category	Description	Example
Design	Drawing/specification issues	GD&T clarification needed
Process	Manufacturing capability	Cpk below target
Tooling	Equipment/fixture issues	Tool modification required
Quality	Inspection/testing gaps	MSA fail, need new gage
Supply	Material/supplier issues	Long lead material
Commercial	Contract/pricing issues	Scope change

Issue Status

Status	Definition	Action
Open	Issue identified, not resolved	Assign owner, target date
In Progress	Work underway	Track to completion
Pending	Waiting on external input	Follow up required
Closed	Issue resolved	Document resolution
Escalated	Risk to timing/quality	Management attention

Issue Tracking Format

## Open Issues Log

| # | Issue | Category | Owner | Target | Status | Notes |
|---|-------|----------|-------|--------|--------|-------|
| 1 | [Description] | [Cat] | [Name] | [Date] | [Status] | [Notes] |

Phase Gate Review Meeting

Agenda Format

Program Status (5 min)
- Timeline status (Green/Yellow/Red)
- Budget status
- Customer communication
Deliverable Review (20 min)
- Checklist walkthrough
- Evidence of completion
- Identify gaps
Risk Review (10 min)
- Open issues summary
- Top 3 risks
- Mitigation status
Gate Decision (5 min)
- Pass / Conditional Pass / Fail
- Actions if conditional
- Next gate schedule

Gate Decision Criteria

Decision	Criteria	Action
Pass	All deliverables complete, no critical issues	Proceed to next phase
Conditional Pass	Minor items open, clear path to close	Proceed with tracking
Fail	Critical items incomplete, significant risk	Hold, develop recovery plan

IATF 16949 Alignment

APQP/PPAP is a core requirement of IATF 16949 (Clause 8.3 - Design and Development).

MNMUK IATF 16949 Context

Certification Target: November 2027 Current Status: ISO 9001 Certified, upgrading to IATF 16949

Reference Documentation:

Compliance Plan: ~/projects/work/docs/compliance/IATF16949_Compliance_Plan.md
Quality Manual: ~/projects/work/docs/work-instructions/QM-001_Quality_Manual.md

IATF Requirements Addressed by This Skill

IATF Clause	Requirement	APQP/PPAP Coverage
8.3.2.1	Design and development planning (APQP)	Full 5-phase APQP
8.3.3.1	Product design inputs	Phase 1 & 2 deliverables
8.3.3.2	Manufacturing process design inputs	Phase 3 deliverables
8.3.4.1	Design outputs (DFMEA, Control Plan)	Phase 2-4 outputs
8.3.5.2	Manufacturing process validation	Phase 4 validation
8.3.6.1	Design and development changes	Re-submission triggers
9.1.1.1	Process capability monitoring	PPAP Element 11

Capability Requirements (per QM-001)

Characteristic	Ppk Minimum	Notes
Critical (CC)	≥1.67	Safety/regulatory impact
Significant (SC)	≥1.33	Fit/function impact
Standard	≥1.00	All other characteristics

PMO Governance

APQP programs at MNMUK are managed through the Programme Management Office (PMO):

Monthly IATF Steering Committee reviews program status
Phase gate reviews align with IATF documentation requirements
Lessons learned feed into quality system continuous improvement

Integration with Related Skills

PFMEA

PFMEA is PPAP Element 6:

Required for all PPAP levels
Must be complete before Gate 3
High RPN items must be addressed

Load: read ~/.claude/skills/Pfmea/SKILL.md

Control Plan

Control Plan is PPAP Element 7:

Pre-launch for Gate 3
Production for Gate 4
Must align with PFMEA

Load: read ~/.claude/skills/Controlplan/SKILL.md

MSA

MSA is PPAP Element 8:

Plan at Gate 3
Results at Gate 4
All gages must pass

Load: read ~/.claude/skills/Msa/SKILL.md

SPC

Initial process studies are PPAP Element 11:

Capability studies at Gate 4
Cpk/Ppk targets must be met

Load: read ~/.claude/skills/Spc/SKILL.md

Internal Audit

APQP program audit requirements:

Phase gate reviews documented
PPAP records auditable
Process effectiveness verified

Load: read ~/.claude/skills/Internalaudit/SKILL.md

Examples

Example 1: Check PPAP readiness

User: "What PPAP elements do I need for Level 3?"
→ Lists all 18 elements with Submit/Retain status
→ Highlights elements to submit
→ Notes MNMUK-specific considerations

Example 2: Run phase gate review

User: "Run Gate 3 checklist for the XYZ project"
→ Loads PhaseGate workflow
→ Walks through Phase 3 deliverables
→ Identifies gaps and assigns actions

Example 3: Generate PSW

User: "Create a PSW for part 12345"
→ Collects required information
→ Generates PSW document
→ Includes all declarations and checklists

Example 4: Track program timing

User: "What's the timeline for our new damper launch?"
→ Loads TimingPlan workflow
→ Creates milestone schedule
→ Identifies critical path items

Supplementary Resources

For detailed guidance: read ~/.claude/skills/Apqpppap/CLAUDE.md

For templates: ls ~/.claude/skills/Apqpppap/templates/

For phase gate checklists: read ~/.claude/skills/Apqpppap/reference/gate-checklists.md

For PPAP element forms: read ~/.claude/skills/Apqpppap/reference/ppap-forms.md