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Free Download PPAP Complete 18 Elements with Excel template & Example
Published 8/2026
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Language: English (US) | Duration: 2h 45m | Size: 2.32 GB
Master PPAP, APQP, PFMEA, Control Plans, MSA, GR&R, SPC, capability and PSW using a complete worked example
What you'll learn
Understand the purpose and significance of all 18 PPAP elements
Build a complete Level 3 PPAP package from product drawing through PSW
Understand how PPAP fits within APQP and the product launch process
Create and review Process Flow Diagrams, PFMEAs and Control Plans
Maintain the PPAP "golden thread" between drawing Requirements, risks, controls and validation evidence
Identify and manage Special Characteristics (SC) and Critical Characteristics (CC)
Conduct and interpret Variable Gauge R&R studies
Understand Attribute GR&R and categorical inspection systems such as GO/NO-GO inspection
Interpret repeatability, reproducibility, %GR&R, ndc, agreement, Kappa, false accepts and false rejects
Perform and interpret process capability studies using Cp and Cpk
Prepare balloon drawings and dimensional inspection reports
Review material certificates, laboratory evidence and performance-test results
Understand Customer Engineering Approval and Authorized Engineering Changes
Apply Customer-Specific Requirements to a PPAP submission
Understand checking aids, master samples, sample production parts and AAR Requirements
Determine when Bulk Material Requirements are applicable
Complete and review a Part Submission Warrant (PSW)
Audit a PPAP package for cross-document inconsistencies before customer submission
Use a populated Excel PPAP workbook as a practical reference for real manufacturing applications
Requirements
No previous PPAP experience is required
Basic knowledge of manufacturing or quality is helpful but not essential
Microsoft Excel or compatible spreadsheet software is recommended for working through the supplied PPAP template
An interest in general quality, supplier quality, manufacturing engineering or quality management
Description
PPAP is much more than completing a Part Submission Warrant.
A robustProduction Part Approval Process (PPAP) demonstrates that customer engineering Requirements have been understood, manufacturing risks have been identified, appropriate process controls have been implemented, measurement systems can be trusted, and the production process is capable of repeatedly manufacturing conforming product.
This practical PPAP course takes you throughall 18 PPAP elements using a complete worked manufacturing example rather than teaching the Requirements only in theory.
Learn PPAP By Building And Reviewing A Complete Level 3 Submission
Throughout the course, we follow an automotiveADC12 aluminium water-pump housing from its engineering drawing through the complete PPAP process.
You will see how information flows from theDesign Record and ballooned drawing into the Process Flow, PFMEA, Control Plan, Measurement System Analysis, dimensional inspection, material and performance testing, process capability studies and finally the Part Submission Warrant (PSW).
This relationship is taught as thePPAP golden thread.
You will learn why good PPAP documentation should not exist as a collection of disconnected forms. A Special Characteristic identified on a drawing should be traceable through process risk analysis, manufacturing controls, measurement validation and production evidence.
All 18 PPAP Elements Explained
The course covers
- Design Records
- Authorized Engineering Change Documents
- Customer Engineering Approval
- Design FMEA applicability
- Process Flow Diagrams
- Process FMEA (PFMEA)
- Control Plans
- Measurement System Analysis (MSA)
- Dimensional Results
- Material and Performance Test Results
- Initial Process Studies and Process Capability
- Qualified Laboratory Documentation
- Appearance Approval Reports (AAR)
- Sample Production Parts
- Master Samples
- Checking Aids
- Customer-Specific Requirements
- Part Submission Warrant (PSW)
You will learn bothwhat each PPAP element is and why it is significant.
Practical MSA, GR&R and Process Capability
The course goes beyond PPAP paperwork.
Using the worked example, you will learn how to conduct and interpret aVariable Gauge R&R study for a precision bore measurement, including repeatability, reproducibility, %GR&R and number of distinct categories (ndc).
You will also learnAttribute GR&R / Attribute Agreement Analysis using a GO/NO-GO inspection system. This includes within-appraiser repeatability, between-appraiser agreement, agreement to a reference standard, Cohen's Kappa, false accepts and false rejects.
We then connect measurement-system capability toSPC and process capability, including the practical interpretation ofCp and Cpk.
This demonstrates an important PPAP principle: process capability results cannot be considered in isolation from the quality of the measurement system used to generate the data.
PFMEA, Process Flow and Control Plan
You will learn how these three core documents work together.
The Process Flow establishes how the product is manufactured.
The PFMEA identifies what could go wrong at each manufacturing operation, the effects and causes of those failures, existing controls and appropriate risk-reduction actions.
The Control Plan then translates those risk decisions into practical production controls, inspection frequencies, measurement methods and reaction plans.
Rather than simply completing templates, you will learn how to challenge whether these documents are genuinely aligned.
Work With A Complete PPAP Excel Example
The course includes a detailed PPAP Excel workbook populated using the water-pump housing example.
This allows you to follow the instructor directly through the documentation and understand how a complete PPAP package fits together.
The worked example includes drawing characteristics, balloon references, Process Flow, PFMEA, Control Plan, MSA planning, Variable GR&R, Attribute GR&R, dimensional results, material testing, performance testing, process capability, checking aids, sample parts, master sample, Customer-Specific Requirements and PSW documentation.
Learn To Think Like A PPAP Reviewer
The course also focuses on common PPAP problems.
You will learn to identify issues such as mismatched drawing revisions, incorrect balloon references, Special Characteristics that disappear between documents, inadequate reaction plans, poor measurement systems, unsupported capability results, missing material traceability, unjustified N/A decisions and PSWs signed despite incomplete supporting evidence.
Knowledge checks and scenario-based exercises reinforce the concepts throughout the course.
By the end of the course, you should be able toprepare, review and challenge a PPAP submission with a much stronger understanding of both the documentation and the engineering logic behind it.
Who this course is for
Supplier Quality Engineers and Supplier Quality Managers
Quality Engineers and Quality Managers
Manufacturing and Process Engineers
APQP and PPAP Engineers
New Product Introduction (NPI) Engineers
Supplier Development Engineers
Automotive and manufacturing professionals
Quality inspectors and metrology professionals moving into quality engineering
Engineering graduates seeking practical PPAP knowledge
Suppliers preparing PPAP submissions for customers
Professionals preparing for interviews or roles involving PPAP, APQP and supplier quality
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