Layered PPAP Submission Audit

Audit template for verifying a Level 3 PPAP submission against AIAG requirements, including the 18 PPAP elements, design records, FMEA, control plan, and process capability evidence.

Submission Scope and Administrative Review

• Submission level is identified as Level 3
• Part number, part name, and customer part number match across all documents
• Engineering change level and document revision status are current
• Submission warrant or equivalent approval form is included and signed
• Submission package includes a complete index of all PPAP elements
• Any customer-specific requirements are identified and included

Design and Engineering Documentation

• Design record is present for the submitted part
• Design record revision matches the latest released customer or internal revision
• Approved engineering change documents are included, if applicable
• Material specifications, performance requirements, and special characteristics are identified
• Customer-approved deviations or waivers are included, if applicable
• Drawing ballooning or characteristic traceability is available for dimensional and test evidence

Process Definition and Risk Controls

• Process flow diagram is included and matches the actual manufacturing sequence
• PFMEA is included, current, and aligned to the submitted process flow
• Control plan is included and aligned to the process flow and PFMEA
• Special characteristics are consistently carried through the drawing, PFMEA, and control plan
• Work instructions or operator instructions are available for key process steps
• Reaction plans are defined for out-of-control or out-of-spec conditions

Measurement, Dimensional, and Capability Evidence

• Dimensional results are included for all drawing characteristics or required sample size
• All special characteristics have documented measurement results
• Measurement system analysis or gage R&R evidence is included where required
• Process capability evidence is included for required characteristics
• Capability indices meet customer or internal acceptance criteria
• Sample parts are identified and traceable to the submitted dimensional evidence

Material, Test, and Supplier Evidence

• Material certifications or conformance reports are included
• Performance, functional, or laboratory test reports are included where required
• Subsupplier or outsourced process approvals are included, if applicable
• Packaging, labeling, and shipping requirements are documented and match customer expectations
• Appearance approval, if applicable, is included and matches the submitted part
• Any required customer-specific test or certification evidence is included

Submission Package Closure

• All required PPAP elements are present for the requested submission level
• Open deficiencies or non-conformances are documented with owners and due dates
• Submission is ready for customer review or approval
• Inspector signature is captured