Introduction to PPQ (Production Part Qualification) Process in Supplier Qualification

Ensuring that every component sourced from suppliers meets defined quality standards is paramount. This blog post aims to provide a first introduction to PPQ, the Production Part Qualification process — a critical part of the supplier qualification framework.

The PPQ process is a component of the broader supplier quality assurance effort, which ensures that supplier parts meet acceptable quality standards and are consistent in performance. The process involves several key activities designed to evaluate the supplier’s ability to produce and deliver parts that meet predefined specifications under actual production conditions at the agreed-upon production rate.

Steps of the PPQ Process

Introduction to PPQ must include process steps, each critical to ensuring the success of the qualification:

1. Design and Specification Review:
   • Purpose: To confirm that the supplier understands the product specifications and has the capability to meet them.
   • Process: Reviewing product design, materials, dimensions, and performance criteria with the supplier.
2. Pre-Production Sampling:
   • Purpose: To evaluate the supplier’s production process capability and the consistency of the output.
   • Process: Suppliers produce a batch of samples which are then tested for compliance with specifications.
3. Process Capability Studies:
   • Purpose: To determine if the supplier’s production process can consistently produce parts at the required specifications.
   • Process: Statistical analysis of sample data from the pre-production runs to assess process stability and capability.
4. Validation Testing:
   • Purpose: To ensure the parts meet all functional, thermal, and mechanical stress tests under simulated or actual operating conditions.
   • Process: Conducting rigorous testing scenarios to validate the quality and reliability of the components.
5. Documentation and Quality Records Review:
   • Purpose: To ensure all necessary documentation and records meet the compliance requirements.
   • Process: Review of process validation records, quality control data, and certification documents.
6. Supplier Audit:
   • Purpose: To assess and verify the supplier’s internal quality management and production processes.
   • Process: On-site audits focusing on production methods, QC practices, and compliance with safety and environmental regulations.

Pros and Cons of the PPQ Process

Pros:

• Enhanced Product Quality and Reliability: The PPQ process helps in identifying and mitigating quality risks early in the production phase.
• Reduced Costs and Waste: By catching defects early, the company can avoid costly reworks and reduce scrap rates.
• Stronger Supplier Relationships: Regular interaction and feedback help build a more collaborative relationship with suppliers.
• Regulatory Compliance: Ensures all products meet regulatory requirements, reducing the risk of non-compliance penalties.

Cons:

• Time-Consuming: The process can be lengthy, particularly when multiple rounds of testing and adjustments are required.
• Resource Intensive: Significant resources are required to manage the PPQ process, including skilled personnel and specialized testing equipment.
• Potential Supplier Resistance: Some suppliers may view the rigorous scrutiny as a barrier, potentially straining relationships.

In the Production Part Qualification (PPQ) process, several key roles from both the buying company and the supplier side are typically involved. Their participation ensures that every aspect of the product qualification is thoroughly evaluated, ensuring adherence to quality and performance standards. Here’s a breakdown of the typical roles (materials procedure participants) involved in a PPQ from both sides:

Buying Company Roles

1. Quality Manager/Engineer:
   • Oversees the PPQ process to ensure that the supplier’s products meet the required specifications and quality standards.
   • Responsible for the final approval of the PPQ documentation and results. Often this role requires a project professional qualification.
2. Procurement/Purchasing Manager:
   • Coordinates with suppliers and manages contractual aspects including timelines, deliverables, and terms that are part of the PPQ process.
   • Ensures that the procurement strategy aligns with the quality expectations.
3. Project Manager:
   • Ensures that the PPQ process aligns with the overall project timelines and milestones.
   • Coordinates different teams within the company to facilitate the PPQ process.
4. Technical/Product Engineer:
   • Provides technical specifications and details required for the PPQ.
   • Assists in assessing whether the supplier’s product meets the technical requirements.
5. Supply Chain Manager:
   • Involved in assessing the impact of the PPQ on the supply chain, especially in terms of logistics and inventory management.
   • Works to integrate the supplier’s products smoothly into the company’s supply chain after successful qualification.

Supplier Side Roles

1. Sales and Account Manager:
   • Acts as the primary contact point for the buying company.
   • Coordinates all communications and ensures that all buyer requirements are clearly understood and met.
2. Quality Assurance Manager:
   • Ensures that the products manufactured for PPQ meet the buyer’s quality standards.
   • Responsible for all quality checks and the final release of products for PPQ.
3. Production Manager:
   • Oversees the production processes involved in the PPQ.
   • Ensures that production schedules and outputs align with the PPQ requirements.
4. Engineering Team:
   • Provides technical expertise and support in modifying product designs or processes as per the PPQ requirements.
   • Implements the technical feedback from the buying company to meet the PPQ standards.
5. Logistics Manager:
   • Manages the logistics of sending samples or final products to the buyer.
   • Coordinates with the buying company’s supply chain team to ensure timely delivery of PPQ samples.

Collaborative Efforts

The PPQ process often requires a high level of collaboration between the buying and supplying sides. Regular meetings, updates, and communications are essential to address any issues swiftly and to maintain the timeline and quality standards set out in the PPQ. In addition, joint development teams consisting of members from both sides may be formed, especially when custom or highly technical products are involved, to facilitate a more integrated and cooperative PPQ process.

Understanding these roles and ensuring that each party fulfills its responsibilities effectively can lead to a successful PPQ process, thereby reducing risks and enhancing the quality and reliability of the products procured.

Understanding PPAP 

Production Part Approval Process (PPAP) and the Production Part Qualification (PPQ) are crucial quality assurance tools. Though they share similar goals, their applications, focus areas, and procedures have some differences.

What is PPAP?

The Production Part Approval Process (PPAP) is a standardized process in the automotive and aerospace industries that helps manufacturers and suppliers communicate and approve production designs and processes before, during, and after manufacture. PPAP is used to ensure that the supplier understands all customer engineering design specifications and requirements and that the process has the potential to produce product consistently meeting these requirements during actual production.

Key Elements of PPAP

PPAP generally consists of 18 elements that may be required by the customer depending on the production level and the product’s impact on quality:

1. Design Documentation: Detailed documentation of the product design.
2. Engineering Change Documentation: Any changes from the original design must be documented and approved.
3. Customer Engineering Approval: Documented customer approval of the product design.
4. Design Failure Mode and Effects Analysis (DFMEA): Analysis of potential failure modes in the design.
5. Process Flow Diagrams: Visual documentation of the manufacturing process.
6. Process Failure Mode and Effects Analysis (PFMEA): Analysis of potential failure modes in the production process.
7. Control Plan: Documentation detailing all control steps in the production process.
8. Measurement System Analysis (MSA): Analysis of the measurement system used for quality control.
9. Dimensional Results: Measurements of the parts produced in the initial production run.
10. Records of Material/Performance Tests: Ensuring materials meet the required specifications and performance standards.
11. Initial Process Studies: Usually statistical process control.
12. Qualified Laboratory Documentation: Proof that the lab meets all required certification standards.
13. Appearance Approval Report: For components affecting aesthetics.
14. Sample Production Parts: Samples from the production run for review.
15. Master Sample: A benchmark sample for comparing future batches.
16. Checking Aids: Jigs, fixtures, and templates used in quality control checks.
17. Customer Specific Requirements: Any additional requirements specific to the customer.
18. Part Submission Warrant (PSW): Summary of the entire PPAP package submitted for approval.

PPAP is primarily used in the automotive industry, and its application is closely guided by specific industry standards:

1. ISO/TS 16949 or now IATF 16949 for automotive.
   • As the successor to ISO/TS 16949, it includes specific provisions for part approval processes, including PPAP. This standard ensures suppliers meet all client and regulatory requirements effectively.
2. AIAG PPAP Manual
   • The Automotive Industry Action Group (AIAG) PPAP manual provides guidelines for conducting the PPAP in a standardized way across the automotive industry. This manual outlines the PPAP requirements and the 18 elements that must be met for a successful PPAP submission.

How Does PPAP Differ from PPQ?

Focus and Scope:

• PPAP is primarily used in the automotive and aerospace industries and is very detailed and stringent, often required for all parts that go into the final product. It is heavily focused on preventing issues by verifying all steps of the production process before mass production begins.
• PPQ, while also focused on quality assurance, can be applied more broadly in various manufacturing sectors. It is generally less prescriptive than PPAP and can be tailored more to the specific needs and standards of the company and industry outside automotive and aerospace.

Procedure and Documentation:

• PPAP requires a formal submission of several documents that demonstrate the supplier’s ability to meet the client’s demands consistently. This includes detailed tests and validations along with customer approvals.
• PPQ tends to be more internally focused and may not always require the same level of customer interaction or formal approval. It focuses on qualifying the production process through internal standards and criteria, which may not be as exhaustive in documentation as PPAP.

Both PPAP and PPQ are designed to ensure quality and reliability in manufacturing processes, but the approach and execution differ due to their industry applications and objectives. 

Summary Introduction to PPQ for buyers

Implementing a robust PPQ process is crucial for maintaining high-quality standards in manufacturing. While it requires significant investment in terms of time and resources, the payoff in reducing downstream issues and enhancing product reliability is invaluable. As we continue to refine our PPQ process, we invite our team members to engage with our Quality Department to learn more about how we can collaboratively enhance our operations and product quality.

Feel free to reach out for a deeper discussion or if you have suggestions to improve our processes further. Together, we can ensure that our products not only meet but exceed our quality expectations.

If you want to have a further introduction to PPQ, the basic level course Product (process) qualification is available at Learn How to Source. This course is designed to guide you through the basic of qualification processes in procurement. You will learn what these processes entail, when and how they should be applied, and explore various standard qualification processes commonly used in the industry.

Note: Illustration to blogpost “Introduction to PPQ for buyers” is created by Chat-GPT on May 1, 2024

Illustrative Case Study: Completion of a Product Part Qualification (PPQ)

Background

XYZ Corporation, a leading manufacturer of electronic consumer goods, was preparing to launch a new line of smart home devices. To ensure the highest quality and reliability of these new products, XYZ Corporation selected ABC Electronics, a well-established supplier, to provide critical components. Due to the strategic importance of these components, XYZ Corporation decided to conduct a PPQ at ABC Electronics’ manufacturing facility.

Why Conduct a PPQ?

XYZ Corporation chose to conduct a PPQ for several reasons:

1. Quality Assurance: To verify that ABC Electronics could consistently produce components that meet XYZ Corporation’s stringent quality standards.
2. Risk Mitigation: To identify and address any potential production issues before mass production began.
3. Compliance: To ensure that ABC Electronics adhered to industry standards and regulatory requirements.
4. Partnership Strengthening: To build a stronger relationship with ABC Electronics by collaborating on quality improvements and process optimization.

PPQ Elements Used

The PPQ audit included the following elements:

1. Facility Inspection: Evaluation of the manufacturing environment, equipment, and processes.
2. Process Validation: Review of production processes and control plans.
3. Quality Control Measures: Examination of quality control procedures and inspection methods.
4. Documentation Review: Verification of documentation related to materials, processes, and quality standards.
5. Sample Testing: Testing of sample components to ensure they meet specified requirements.
6. Training and Competency: Assessment of the training programs and competency of personnel.

Completion of PPQ Elements

1. Facility Inspection: The procurement specialist from XYZ Corporation, John, along with ABC Electronics’ quality manager, Sarah, conducted a detailed walkthrough of the production area. They inspected the cleanliness, organization, and maintenance of machinery. They also reviewed the layout to ensure efficient workflow and minimal risk of contamination or damage to components.
2. Process Validation: John and Sarah examined the production flowcharts and control plans. They observed the manufacturing process in action, from raw material handling to final assembly. Key focus areas included adherence to process parameters, calibration of equipment, and implementation of control measures.
3. Quality Control Measures: The audit team reviewed the quality control checkpoints and inspection stations. They evaluated the procedures for in-process and final inspections, including the use of statistical process control (SPC) charts and defect tracking systems.
4. Documentation Review: John requested and reviewed various documents, including material specifications, process control plans, and quality manuals. He checked for completeness, accuracy, and compliance with industry standards such as ISO 9001.
5. Sample Testing: Sample components were selected randomly from different production batches. These samples underwent rigorous testing in ABC Electronics’ quality lab, where measurements and performance tests were conducted to verify compliance with XYZ Corporation’s specifications.
6. Training and Competency: The audit included interviews with key personnel and a review of their training records. John assessed the competency of operators and quality inspectors, ensuring they were adequately trained and knowledgeable about their tasks.

Data Sharing and Completion Sign-Off

After completing the audit, John compiled a comprehensive PPQ report detailing the findings and observations. This report included:

• Photographs and notes from the facility inspection.
• Results of process validation and sample testing.
• Documentation review outcomes.
• Identified areas for improvement and recommendations.

The report was shared with ABC Electronics via a secure cloud-based collaboration platform. Both parties reviewed the report and discussed the findings in a follow-up meeting. John and Sarah addressed any concerns and agreed on an action plan for continuous improvement.

Finally, both parties signed off on the PPQ completion. The sign-off included:

• A formal approval letter from XYZ Corporation, acknowledging the successful completion of the PPQ.
• A commitment from ABC Electronics to implement the recommended improvements and maintain the agreed-upon quality standards.
• Digital signatures from John (procurement specialist, XYZ Corporation) and Sarah (quality manager, ABC Electronics) on the PPQ report and approval letter.

This successful completion of the PPQ audit reinforced the partnership between XYZ Corporation and ABC Electronics, setting the stage for a smooth production launch and ensuring high-quality components for the new smart home devices.

Extra: Advanced Product Quality Planning (APQP)

APQP is a framework of procedures and techniques used to develop products in industries that require high-quality standards. It ensures that the product development process is thorough and efficient, leading to products that meet customer expectations.