What are the five PPAP levels?

Before a PPAP submission can take place, production tooling must already be proven capable of producing consistent, accurate parts. The quality and design of the tool directly affect part reliability and process stability. You can learn more about typical injection moulding tooling costs here.

• Level 1 – Part Submission Warrant (PSW) only
• Level 2 – PSW with product samples and limited supporting data
• Level 3 – PSW with product samples and complete supporting data
• Level 4 – PSW and other requirements as defined by the customer
• Level 5 – PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location

Each submission level needs a PSW, but as you can see, each level above the first requires some more supporting information. A checklist of 18 potential aspects must be delivered to the client or kept by the supplier and provided to the customer upon request.

PPAP is commonly used in plastic injection moulding services to ensure parts meet customer specifications before full production begins.

But let’s start at the beginning and examine what makes each level unique.

What is required for a Level 1 PPAP submission?

While a level 1 submission is listed as ‘PSW only,’ this is not entirely correct. An appearance approval report must be submitted to the customer for designated appearance items. A bulk material requirements checklist must be submitted when submitting a bulk material PPAP.

What is required for a level 2 PPAP submission?

A level 2 PPAP requires more supporting data from the customer than a level 1, but it does not cover all on the list of 18 potential requirements. A level 2 PPAP would require design records for saleable items, as well as all additional components and information.

Dimensional results, materials and performance test findings, as well as qualified laboratory paperwork, would also be required. As you can see, the amount of information rises as the levels go.

It is also at this level that a sample product must be supplied to the client rather than being retained by the provider.

What is required for a level 3 PPAP submission?

As seen in the checklist above, this level requires ‘full’ rather than ‘limited’ supporting data. That implies you’ll go over everything you covered in level 2 plus a lot more.

At addition to everything in level 2, the supplier must supply data to the customer such as customer engineering approval, design FMEA, process flow diagrams, control plans, and measurement system analysis studies. The supplier would also be required to provide the customer with any preliminary process studies and compliance documents.

What is required for a level 4 PPAP submission?

This is when things start to get interesting. While the mandatory PSW and, if applicable, bulk material needs checklist will always be provided to the customer, the remainder of the checklist is the customer’s responsibility.

Regardless of what the customer wants to be submitted, it is critical for the supplier to have each of the 18 requirements on site so that they can be delivered later if necessary.

What is required for a level 5 PPAP submission?

Level 5 PPAP submissions differ from the other four in that they are complete but must be examined at the supplier’s facilities. That implies a PSW and all accompanying papers must be developed, but the client will evaluate them with the supplier.

How do you choose the level of PPAP submission?

The PPAP submission level chosen is determined by a variety of distinct criteria. Customers may have a desired PPAP submission level for the majority of the parts they purchase, but individual parts may require a different degree of submission.

It also relies on the nature of the parts submitted. Obviously, bulk material orders will have specialised criteria, but any other part may have additional concerns that need a client to use one of the PPAP submission levels.

If you’re reviewing plastic injection moulding companies for critical components, this guide to choosing a precision injection moulding supplier explains what to look for and how to avoid common issues.