PPAP Submission Checklist.
All 18 PPAP elements per AIAG 4th edition. Track your submission status by Level 1–5 and never miss a customer requirement again.
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AS9102, balloon drawings, capability data — all in one workflow. Tata, Mahindra, Bajaj variations included.
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Indian OEM variations
- Tata Motors: Requires additional Lab Capability Survey + supplier ranking sheet (Level 3+)
- Mahindra & Mahindra: Material composition certificate must be from NABL-accredited lab
- Bajaj Auto: Run-at-rate (300-piece capability run) replaces standard Initial Process Study at Level 3
- Maruti Suzuki: Customer-specific MIS (Material Information Sheet) and IMDS submission required
- Hero MotoCorp: Q-Wall checklist + dimensional layout in Hero-prescribed format
What is PPAP?
PPAP (Production Part Approval Process) is the AIAG-defined process for proving to your customer that you can consistently produce parts meeting all specifications. It's the gate between prototype and production volume — and you can't ship without it.
The 18 PPAP Elements (AIAG 4th Edition)
- Design Records
- Authorized Engineering Change Documents
- Customer Engineering Approval
- Design FMEA
- Process Flow Diagram
- Process FMEA (PFMEA)
- Control Plan
- Measurement System Analysis (MSA / Gauge R&R)
- Dimensional Results
- Records of Material / Performance Tests
- Initial Process Studies (Cp/Cpk)
- Qualified Laboratory Documentation
- Appearance Approval Report (if applicable)
- Sample Production Parts
- Master Sample
- Checking Aids
- Customer-Specific Requirements
- Part Submission Warrant (PSW)
PPAP Submission Levels
- Level 1 — PSW only. For low-risk changes.
- Level 2 — PSW + product samples + limited supporting data.
- Level 3 — Default for most parts. Full submission with samples and data.
- Level 4 — PSW + customer-defined requirements (custom).
- Level 5 — Full submission reviewed AT supplier site (audit).
Most Common PPAP Rejection Reasons
- Stale drawing revision — Element 1 must match the released customer drawing exactly.
- Insufficient capability data — Element 11 needs Cpk ≥ 1.33 from real production runs, not a single sample.
- Weak MSA — Element 10 must show the gauge is capable for the tolerance being measured.
- Missing PFMEA links — Element 6 must connect failure modes to specific Control Plan items in Element 7.
- Unsigned PSW — Element 18 requires signatures from Quality, Engineering, and authorized personnel.
Indian Customer Variations
Each major Indian OEM has slightly different PPAP requirements:
- Tata Motors — TML-format PSW, additional supplier rating documents.
- Mahindra — Specific PFMEA template, control plan format.
- Bajaj Auto — Quarterly capability re-verification required.
- Hero MotoCorp — Heat treatment and material validation emphasis.
Workflow Tools
PPAP draws from many tools — run Cp/Cpk studies for Element 11, Gauge R&R for Element 10, FMEA RPN analysis for Element 6, and AQL sampling plans for ongoing control. For aerospace customers, the AS9102 Form 3 covers similar ground.