PPAP, or Production Part Approval Process, is a critical step in the automotive supply chain that is meant to ensure the quality of parts being produced by suppliers. The PPAP process is used by automotive Original Equipment Manufacturers (OEMs) to verify that the parts produced by suppliers meet their specifications, quality standards, and other requirements. However, submitting PPAP can be a challenging process, and there are many reasons why OEM customers reject initial PPAP submissions. In this article, we will discuss the top challenges faced when submitting PPAP to automotive OEM customers and the top reasons why OEM customers reject initial PPAP submissions.
Tier-1 and Tier-2 automotive suppliers face similar challenges when submitting PPAP to their customers, but there are some differences in the specific challenges they face. Here are the primary challenges that Tier-1 and Tier-2 automotive suppliers face when submitting PPAP:
Challenges faced by Tier-1 Automotive Suppliers Submitting PPAP to OEMs:
Challenges faced by Tier-2 Automotive Suppliers:
Regardless of whether a supplier is a Tier-1 or Tier-2 supplier, effective communication with the customer, ensuring that all requirements are met, providing all required documentation, and conducting all necessary tests and validations are critical to a successful PPAP submission.
PPAP submissions that do not meet the requirements set by the Original Equipment Manufacturer (OEM) can be rejected. Here are the top reasons why OEMs reject PPAP submissions:
To ensure a successful PPAP submission, suppliers must communicate effectively with the customer, ensure that all requirements are met, provide all required documentation, and conduct all necessary tests and validations.
As discussed above, PPAP submissions that do not meet the requirements set by the Original Equipment Manufacturer (OEM) can be rejected, resulting in delays and increased costs. Here are some ways to improve the PPAP process and reduce the risk of rejection by OEM customers:
Improving the PPAP process can help suppliers to reduce the risk of rejection by OEM customers. Clear communication, early engagement, a robust quality management system, effective documentation, the use of technology, and continuous improvement are some ways to improve the PPAP process. By implementing these improvements, suppliers can increase their chances of a successful PPAP submission and reduce delays and costs associated with rejected submissions.
In summary, automotive manufacturers throughout the supply chain must be aware of the key challenges and reasons for PPAP rejection, such as nonconformance with customer requirements, incomplete PPAP submission, test and validation failures, and inadequate communication. To improve the PPAP process and reduce the risk of rejection, suggested actions include clear communication, early engagement, a robust quality management system, effective documentation, the use of technology, and continuous improvement. Specifically, the use of software can streamline the PPAP process by managing documentation, tracking testing and validation results, and managing timelines. By implementing these improvements, automotive manufacturers can increase their chances of a successful PPAP submission and reduce delays and costs associated with rejected submissions.
IntellaQuest offers a suite of SaaS applications specifically tailored to improve the APQP/PPAP process throughout the supply chain, with our solutions being deployed in OEM and sub-tier plants alike. ProjectQuest, FMEAQuest, InspectionQuest, and PPAPQuest were all designed to work together to streamline the APQP and PPAP process for automotive firms of any size, making it simple to plan APQP projects and generate, control, submit, and review all of the necessary data and documentation. If you’re looking to improve your PPAP process to increase the quality of your submissions and reduce risk of quality issues and PPAP submission rejections, reach out to request a demo or take advantage of our 60-day proof of concept (POC) at no cost.