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PPAP & New Product Launch
New Product
PPAP per AIAG: flow, FMEA, control plan, MSA, capability, run-at-rate. On-time customer approval and zero launch escapes.
Executive Summary
A new product launch required customer approval and evidence of capable processes. This project delivered PPAP per AIAG: process flow, FMEA, control plan, MSA, capability studies, and run-at-rate. Outcomes: on-time PPAP approval, zero launch escapes, and a repeatable launch checklist.
- On-time PPAP approval from customer
- Zero launch escapes in first 90 days
- Repeatable launch checklist for future programs
Context & Problem
Previous launches had late PPAPs and post-launch issues. The organization needed a structured approach to gather and present PPAP evidence and ensure processes were stable before volume ramp.
Methodology & Frameworks
Process flow, FMEA, control plan aligned. MSA acceptable before capability. Cpk/Pp for key characteristics. Run-at-rate to verify no bottlenecks or quality issues at volume.
Implementation
A cross-functional team owned PPAP deliverables. FMEA and control plan were built early; MSA and capability were completed before run-at-rate. All documents were packaged for customer submission. A launch checklist ensured nothing was missed.
Outcomes
- On-time PPAP approval—customer accepted with no major findings.
- Zero launch escapes in the first 90 days of production.
- Repeatable checklist for future programs.
Lessons Learned
Start PPAP early; MSA and capability take time. Align FMEA, control plan, and process flow. Run-at-rate surfaces issues that bench trials miss. A single owner for PPAP coordination prevented dropped items.