From Paperwork to Performance: Rethinking the process

By Levy Carlos De Campos

PPAP (Production Part Approval Process) is a formalized quality assurance process used mainly in automotive, aerospace, and other high-reliability industries to ensure a supplier can consistently produce parts that meet specifications.

Bureaucratic PPAP

Mindset: “Follow the checklist to the letter, no matter what.”

Characteristics:

• Focus on document completion over true process verification.

• Treats PPAP as a compliance exercise rather than a risk-control tool.

• Often results in large, repetitive binders of data, with little added value to actual production.

• Can cause delays, redundant testing, and overhead costs.

Example: Running a full-blown 18-element PPAP for a trivial design tweak that doesn’t impact fit, form, or function.

Risks:

• Waste of engineering/manufacturing time.

• Slower launches.

• “Check-the-box” mentality instead of real process validation.

Pragmatic PPAP

Mindset: “Ensure the part meets requirements—smartly and efficiently.”

Characteristics:

• Tailors the PPAP level and documentation to the actual risk and complexity of the part.

• Uses data already collected in normal quality processes instead of duplicating effort.

• Focuses on critical-to-quality features and process stability.

• Leverages technology (digital submissions, linked process data, SPC systems) to cut time and errors.

Example: For a low-risk cosmetic change, perform only the few PPAP elements that prove capability and compliance, skipping redundant steps.

Benefits:

• Faster time-to-market.

• Reduced costs without compromising quality.

• Encourages a culture of value-added quality work rather than paperwork.

In the Injection Molding World

Bureaucratic PPAP often happens when OEMs use rigid templates without understanding molding process nuances—e.g., asking for irrelevant material test data or duplicate capability studies.

Pragmatic PPAP focuses on molding-specific risk points:

• Material lot consistency.

• Mold wear and dimensional stability.

• Process window validation.

• First-article inspections tied to real production settings.