First article inspection vs PPAP
A first article inspection (FAI) proves that the first parts from the production tool and process meet every drawing requirement. PPAP, the Production Part Approval Process from the AIAG automotive manuals, is broader: it proves that the process will keep producing conforming parts at the quoted rate, and it bundles the FAI results with process documents. A non-automotive buyer usually needs an FAI; an automotive buyer names a PPAP submission level.
| First article inspection | PPAP | |
|---|---|---|
| Proves | The first parts conform | The production process conforms and is capable |
| Contents | Ballooned drawing, dimensional results, material and test records | Up to 18 elements, depending on the submission level |
| Requested by | Most industrial buyers | Automotive customers; some others adopt it |
| Repeated | On tool or drawing change | On change, per customer rules |
What a casting first-article package contains
- Ballooned drawing. Every characteristic numbered, at the current revision.
- Dimensional report. Requirement and actual for each balloon, in the delivered condition, from the agreed datums.
- Material. Composition of the melt; mechanical results with specimen type and location, and heat-treatment condition. For what to check on the material certificate itself, see aluminum casting material certificates.
- Internal soundness. X-ray images and grades for the agreed zones, if required.
- Leak test. Medium, pressure, method, limit and result, if required.
- Finish. Coating, thickness, masking and appearance checks, if required.
- Traceability. Tool and cavity, lot, date, sample IDs.
PPAP elements that apply to castings
A PPAP submission level decides which elements are sent and which are retained at the plant. For castings the elements that carry the most weight are the process flow, PFMEA and control plan (where porosity, leak and dimensional risks are controlled), the dimensional results, material and performance test results, initial process studies on critical characteristics, and measurement system analysis for the gauges that release parts. Name the level and any customer-specific requirements in the RFQ so the scope is quoted, not discovered.
Design records and design FMEA belong to the design owner. Our IATF 16949 certificate excludes clause 8.3 (product design), so design authority stays with you.
Agree the sample run before tooling
- Sample quantity and which parts are measured in full
- Whether samples come from the production tool and process
- Condition at measurement: after T6, machining and finish
- Who witnesses: remote review, on-site or live video
- What happens to a characteristic that fails: re-sample or deviation
Changes after approval
A drawing revision, tool repair that touches a cavity, alloy or heat-treatment change, or a move of the process is a change to an approved part. Agree in advance which changes need notification, which need re-submission, and which characteristics are re-verified.
Casting inspection plan Casting lot release Automotive structural castings