新项目量产前，客户一句"把 PPAP 交过来"，很多人第一反应是填张 PSW。其实 PPAP 第四版要的是一整套 18 项交付物，本质一句话：证明你批量生产的零件和过程，与当初验证批准的状态完全一致。18 项听着多，按"产品、过程、实物"三条线一理就清。
▌ 产品线（1~5）：证明零件设计对了
- 设计记录：最终版图纸或 CAD 数据，电子版要附图例和公差标注副本；
- 工程更改文件：已批准未上图纸的变更，单独列授权文件；
- 顾客工程批准：客户要求时，出示工程批准证据；
- 设计 FMEA：有设计职责的组织必须做，提前想清产品怎么失效；
- 材质报告与聚合物标示：材质数据走 IMDS；塑料满 100 克、橡胶满 200 克按 ISO 标准打标示。
▌ 过程线（6~13）：证明制造过程稳得住
- 过程流程图：入料到出货的步骤图，是 PFMEA 和控制计划的骨架；
- 过程 FMEA：预判每道工序怎么失效、后果多重、靠什么防；
- 控制计划：写清每个特性怎么控制、检多少件、超差怎么反应；
- 测量系统分析 MSA：量具的 GRR、偏倚、线性、稳定性——量具不可信，后面全白做；
- 全尺寸测量结果：所有尺寸按图纸测一遍，多腔模每腔都测，并指明标准样件；
- 材料/性能试验结果：化学、物理、性能试验，留原始记录；
- 初始过程研究：关键特性算 Cpk 或 Ppk，至少 25 组、100 个读数；
- 合格实验室文件：试验必须出自有资质认可的实验室，外部实验室用正式报告纸。
▌ 实物线（14~18）：证明看得见摸得着
- 外观批准报告 AAR：有颜色、纹理要求的零件，单独报外观；
- 生产件样品：从有效生产批次取样交客户；
- 标准样品：留存一件当对照基准，与批准记录同期限保存；
- 检查辅具：客户要求的专用检具、夹具随件提交并做 MSA；
- 零件提交保证书 PSW：全部结果汇总、授权人签字，18 项的总开关。
▌ 硬性门槛：300 件与 1.67 两条线
- 有效生产：1 到 8 小时量产、至少 300 件连续生产，用正式工装、量具和人员；
- 能力门槛：初始过程指数大于 1.67 直接接受，1.33 到 1.67 有条件接受，小于 1.33 不通过；
- 提交等级：1 到 5 级，等级 3 常见——保证书、样品加全部数据；等级 5 最省事——数据留现场备查。
▌ 什么时候要重新提交
新零件、纠正既往不符合、设计记录或材料变更、工装转移或重新布置、停线超 12 个月复产——手册表 3.2 列出的情形都必须重新提交。原则一句话：变更先通知客户，批准后再实施。另外 18 项不是每项都适用：没外观要求不用 AAR，没设计职责不用 DFMEA。
记一句：交 PPAP 不是应付客户，是给批量生产发通行证——证据链完整，客户批得放心，自己产得安心。
想让 PPAP 从"凑资料"变成一次过的证据链？续创的核心工具实操课带你逐项演练。欢迎联系续创信息技术咨询。
Before a new program launches, the customer says "send us the PPAP", and many people's first reaction is to fill in a PSW and be done. In fact, PPAP Fourth Edition demands a full set of 18 deliverables with one single message: prove with evidence that the parts and process you run in series production are exactly what was validated and approved. Eighteen items sound like a lot — sort them along three lines, "product, process, physical evidence", and the picture clears up.
▌ Product Line (Items 1–5): Proving the Part Design Is Right
- Design records: the final drawing or CAD data; electronic copies must include the legend and a copy of tolerance callouts;
- Engineering change documents: changes approved but not yet incorporated into the drawing, listed with their authorisation;
- Customer engineering approval: evidence of engineering approval when the customer requires it;
- Design FMEA: mandatory for organisations with product-design responsibility — think through how the product could fail in advance;
- Material reports and polymer marking: material data goes through IMDS; plastic parts of 100 g and rubber parts of 200 g or more are marked per ISO standards.
▌ Process Line (Items 6–13): Proving the Process Holds Up
- Process flow diagram: the step-by-step map from incoming material to shipping — the backbone of the PFMEA and control plan;
- Process FMEA: anticipates how each operation could fail, how severe the effect is, and what prevents it;
- Control plan: for every characteristic — the control method, the sample size, and the reaction plan when out of spec;
- Measurement systems analysis (MSA): gauge R&R, bias, linearity and stability — if the gauge cannot be trusted, everything after it is wasted;
- Dimensional results: every dimension measured per the drawing; for multi-cavity tools, every cavity is measured, with the master sample identified;
- Material and performance test results: chemical, physical and performance tests with original records kept;
- Initial process studies: Cpk or Ppk on key characteristics — at least 25 subgroups and 100 readings to prove capability;
- Qualified laboratory documentation: tests must come from an accredited laboratory; external labs report on formal letterhead.
▌ Physical Line (Items 14–18): Evidence You Can See and Touch
- Appearance Approval Report (AAR): a separate appearance submission for parts with colour or texture requirements;
- Sample production parts: samples taken from a significant production run and shipped to the customer;
- Master sample: one part retained as the comparison baseline, kept for the same period as the approval records;
- Checking aids: customer-required dedicated gauges and fixtures submitted with the parts, each with its own MSA;
- Part Submission Warrant (PSW): all results summarised and signed by the authorised person — the master switch of all 18 items.
▌ Hard Thresholds: 300 Pieces and the 1.67 Line
- Significant production run: 1 to 8 hours of series production, at least 300 consecutive pieces, using production tooling, gauges and personnel;
- Capability threshold: an initial process index above 1.67 is accepted outright, 1.33 to 1.67 is conditionally accepted, below 1.33 is rejected;
- Submission levels: levels 1 to 5. Level 3 is the common choice — warrant, samples and complete data; level 5 is the lightest — data kept on site for review.
▌ When Resubmission Is Required
New parts, correction of a previous discrepancy, changes to design records or materials, tooling transfer or rearrangement, and restarting production after more than 12 months of stoppage — Table 3.2 of the manual lists these situations, and each requires a fresh PPAP submission. The principle in one sentence: notify the customer of changes first, implement only after approval. Also, not all 18 items apply: no appearance requirement means no AAR, no design responsibility means no DFMEA.
One line to remember: submitting PPAP is not about satisfying the customer — it is issuing a passport for series production. A complete chain of evidence lets the customer approve with confidence and lets you produce with peace of mind.
Want to turn PPAP from scrambling for documents into a first-pass evidence chain? CINO's core-tools hands-on courses walk you through every item. Contact CINO Information Technology Consulting.