Failure Mode and Effects Analysis (FMEA) is a proactive risk assessment tool used during product and process development, while PPAP (Production Part Approval Process) is the formal evidence of production readiness.
Although they are separate deliverables, FMEA directly drives several PPAP elements—especially those related to quality control, validation, and customer satisfaction.
✅ FMEA identifies the risks →
✅ PPAP confirms the risks are controlled and the process is stable.
In this documentation, we’ll walk through how FMEA links to key PPAP deliverables like:
- Control Plan
- Dimensional Results
- Appearance Approval Report (AAR)
- MSA Studies
- Capability Studies
- Process Flow Diagram
- PSW (Part Submission Warrant)
🔧 PPAP & Core Tools Framework #
PPAP is one of the five core tools (APQP, PPAP, FMEA, MSA, SPC) defined by AIAG. They are designed to work in harmony, and FMEA sits at the core of risk identification and control planning.
✅ FMEA Linkage to Key PPAP Elements #
Let’s go PPAP element by element and understand how PFMEA (and sometimes DFMEA) supports each:
1. 📋 Control Plan
Most Direct Link.
- The Control Plan is built from the PFMEA, especially:
- Prevention controls → Process control methods
- Detection controls → Inspection/monitoring methods
- Special characteristics → Enhanced control methods
PFMEA Step 5–7 (Risk Analysis → Optimization → Documentation) inform the:
- Control Methods
- Frequency
- Reaction Plans
✅ Without PFMEA, Control Plan would lack justification for controls.
2. 📏 Dimensional Results
- PFMEA identifies product characteristics that are critical to function.
- These characteristics are translated to inspection features in:
- Drawings
- Control Plans
- Dimensional reports
✅ Failure modes related to fit/form/function in DFMEA or PFMEA define what must be measured.
Example:
If PFMEA defines “misalignment due to hole position” → Dimensional Results must include hole location measurements on submitted parts.
3. 🎨 Appearance Approval Report (AAR)
- FMEA (DFMEA or PFMEA) identifies potential failure modes like:
- Surface defects
- Color mismatch
- Improper texture or gloss
- These are then included as special appearance-related characteristics, which must be:
- Controlled in production
- Validated via AAR submission
✅ FMEA flags risks related to visual aspects → AAR verifies they’re acceptable to the customer.
4. 📊 Measurement System Analysis (MSA)
- PFMEA identifies critical and significant characteristics that require precise measurement.
- For these, MSA studies are conducted to:
- Validate gages
- Verify measurement repeatability and reproducibility
✅ FMEA drives which measurements need GR&R studies due to their impact on product quality.
5. 📈 Process Capability Studies
- Characteristics with high S/O ratings in PFMEA (e.g., hole diameter affecting fit) need:
- Statistical validation of process capability (Cp, Cpk)
- These are often special characteristics marked in the PFMEA and Control Plan.
✅ FMEA helps prioritize which features require capability studies before final PPAP submission.
6. 🔁 Process Flow Diagram (PFD)
- PFMEA Step 2 (Structure Analysis) uses the same structure and flow as the Process Flow Diagram.
✅ FMEA ensures risks are evaluated at each process step in the flow → PFD provides a visual reference in PPAP.
7. 📄 Part Submission Warrant (PSW)
- PSW is the summary document for all PPAP submissions.
- It includes confirmation that:
- FMEA has been completed
- All special characteristics are addressed
- Control Plan, MSA, Capability, and other validations are done
✅ FMEA serves as the foundation of the “Yes” answers on PSW.
🔗 Traceability Table: FMEA to PPAP Deliverables #
| FMEA Output | PPAP Element It Supports |
|---|---|
| Failure Modes, Effects, Causes | Control Plan, Process Flow, Dimensional Results |
| Special Characteristics (SC/CC) | Control Plan, Dimensional Results, AAR |
| Prevention & Detection Controls | Control Plan, MSA, PSW |
| Recommended Actions | Control Plan (updated methods), PSW |
| Product/Process Requirements | Dimensional Results, AAR |
| Measurement Needs | MSA (GR&R), SPC, Capability Studies |
🎯 Summary: Why This Linkage Matters #
- ✅ Ensures risk-based thinking is applied throughout PPAP
- ✅ Supports customer-specific requirements for traceability
- ✅ Builds confidence in the manufacturing process
- ✅ Forms the basis for audit readiness and compliance
- ✅ Reduces the chance of failures reaching the customer
FMEA is not just a risk document—it’s the blueprint that drives many PPAP deliverables.
🧠 Pro Tip #
Keep your FMEA document reference numbers and revision levels recorded in your:
- Control Plan
- MSA forms
- Capability reports
- PSW
This provides traceability during audits and process changes.
📚 Related Resources #
- PPAP Requirements Explained
- What is PFMEA? Step-by-Step Guide
- Control Plan: Step-by-Step Guide
- Dimensional Results in PPAP
- AAR in PPAP
- MSA (GR&R) Studies
- PSW Form Explained
✅ Conclusion #
The FMEA isn’t a standalone tool—it’s the foundation of your PPAP submission package. Nearly every PPAP element—Control Plan, Dimensional Results, AAR, MSA, PSW—relies on the groundwork laid by FMEA.
By ensuring this linkage is consistent, traceable, and robust, you’re not only ensuring compliance—but building a quality-first manufacturing system.
“What you analyze in FMEA, you prove in PPAP.”
