Quality assurance is at the heart of every successful manufacturing operation, and at Thesun Industry, we know how critical it is to deliver parts that meet your exacting standards for safety, performance, and compliance. Whether you’re launching a new medical device, upgrading an automotive component, or introducing an electronics assembly, you need confidence that your injection-molded parts will perform consistently batch after batch. That’s why we offer a true one-stop service for manufacturing and quality control, including our comprehensive Production Part Approval Process (PPAP). If you’ve ever wondered how PPAP fits into your project timeline or what’s involved in a PPAP submission, keep reading—this guide will demystify the process and show you how Thesun Industry integrates PPAP seamlessly into our manufacturing workflow.
What Is the Production Part Approval Process (PPAP)?
Originally developed by the automotive industry’s leading voices in quality engineering, PPAP is a structured, standardized approach designed to confirm that a supplier’s manufacturing process can consistently produce parts that meet customer requirements. The Automotive Industry Action Group (AIAG) formalized the PPAP standard, and it quickly became a cornerstone of automotive supply chains worldwide. Over time, industries as diverse as aerospace, medical devices, and consumer electronics have adopted PPAP to ensure regulatory compliance, product safety, and performance reliability.
In practice, PPAP accomplishes three key objectives:
- It documents that your part design specifications and engineering requirements are fully understood.
- It verifies that our manufacturing process can achieve those specifications consistently.
- It provides traceable evidence—through documentation and testing—that builds confidence before full production begins.
How Thesun Industry Integrates PPAP into Our Manufacturing Process
At Thesun Industry, PPAP is not a standalone “add-on” inspection; it is woven into our standard manufacturing workflow. From the moment you request a quote, our team is ready to support a PPAP submission as part of our one-stop service for injection molding and production. Here’s how it works:
- Design for Manufacturability (DFM) Analysis
Before a single part is molded, our engineers conduct a thorough DFM review of your CAD model. We analyze wall thicknesses, draft angles, gate locations, and cooling channels to identify any potential manufacturability risks. This early collaboration helps reduce the likelihood of defects and sets the stage for a successful PPAP submission. - Dimensional Verification
We measure up to four plane-to-plane and outside diameter dimensions (X, Y, Z) against your quoted tolerances. These baseline measurements are captured in our PPAP documentation, showing that the first run of parts conforms precisely to your design specifications. - Standard Level 3 PPAP Package
By default, our PPAP package aligns with AIAG’s Level 3 requirements. This comprehensive submission includes:- Process Flow Diagram
- Process Failure Mode and Effects Analysis (PFMEA)
- Control Plan and Inspection Plan
- Dimensional Measurement Results
- Material Certificates and Certificates of Conformance
- Part Submission Warrant (PSW)
These elements together demonstrate the stability and capability of our manufacturing process.
- Batch Records and Master Samples
For every mold we build, we retain the master sample and batch production records. This traceability ensures that if you ever need to review the history of a particular lot, we can provide complete documentation from initial mold trials through full production. - Custom PPAP Options
If your project demands additional scrutiny—perhaps you need an external certified inspection partner or a higher PPAP level—we’ll work with you to customize the PPAP scope. Custom PPAPs typically require an extra 11+ business days and are quoted alongside your production order. This flexibility ensures you get exactly the level of validation you require.
The PPAP Submission Process at Thesun Industry
When you decide to include PPAP in your project, here’s the step-by-step flow you can expect:
- Quote Stage
- Check the PPAP option on our quotation form.
- Provide your part drawing, specifications, and any special requirements.
- Pre-Production Planning
- We perform DFM analysis and develop the process flow chart and PFMEA.
- A control plan is established, detailing measurement methods and inspection intervals.
- Prototype and Initial Run
- We mold a sample batch of parts under production conditions.
- Dimensional and visual inspections are conducted, and results are recorded.
- PPAP Package Assembly
- We compile the required documents: dimensional data, material certificates, PSW, etc.
- All elements are reviewed internally for accuracy before submission.
- Customer Review and Approval
- We deliver the PPAP package for your evaluation.
- Upon your approval, we move into full production, confident in our process capability.
Why Industries Rely on PPAP
Automotive
When building vehicles, every component must meet stringent safety and performance criteria. PPAP is mandatory in automotive supply chains, ensuring that parts—from engine mounts to interior trim—are produced with unwavering precision.
Aerospace
Aerospace applications demand absolute reliability under extreme conditions. PPAP helps aerospace OEMs and Tier 1 suppliers validate new parts or process changes, reducing the risk of in-flight failures.
Medical Devices
Regulatory bodies such as the FDA and EU MDR require robust quality systems. By adopting PPAP, medical device manufacturers demonstrate controlled processes and traceable part history—a critical factor for audit readiness.
Consumer Electronics and Beyond
From smartphones to home appliances, PPAP offers any manufacturer a path to higher product quality, lower defect rates, and enhanced customer satisfaction.
The Benefits of Embracing PPAP
The AIAG sums up the value of PPAP succinctly:
- Consistent Approval Process: A uniform approach to part validation.
- Conformance Assurance: Clear evidence that parts meet customer requirements.
- Process Stability Verification: Data-driven confirmation that processes run within control limits.
- Controlled Change Management: A formal mechanism for approving any design or process revisions.
Beyond PPAP: Additional Inspection Services
In addition to our standard and custom PPAP offerings, Thesun Industry provides a full suite of inspection and documentation options, including:
- First Article Inspection (FAI) for early production validation.
- Critical-to-Quality (CTQ) Inspections focusing on the most essential dimensions.
- Digital Inspection Reports (DIRs) for comprehensive, data-rich documentation.
Our goal is to deliver a complete manufacturing and quality solution, all under one roof.
At Thesun Industry, we’re more than a contract manufacturer—we’re your partner in delivering world-class parts. Our one-stop service integrates precision manufacturing with robust quality systems like PPAP, ensuring that your production runs smoothly from design through delivery. If you’re ready to experience the confidence that comes with a fully documented, validated manufacturing process, get in touch with our team today. Let us show you how PPAP and our end-to-end manufacturing capabilities can elevate your next project.
Ready to learn more or request a custom PPAP quote? Contact Thesun Industry at [email protected] and let’s ensure your parts exceed expectations—every time.
