PPAP & AVL

Overview

PPAP & AVL brings together the tracking of the 18 elements under AIAG PPAP 4th Edition, Approved Vendor List (AVL) management and an IATF 16949 §8.4.1 compliant supplier scorecard in a single module. You open an AVL record for a part/supplier pair, the required elements are created automatically according to the PPAP level, the submission goes to the customer for approval as the elements are completed, and the result is reflected back on the AVL record automatically.

Key Concepts

• AVL record — the approval record pairing a part number with a supplier; it carries tier, unit cost, lead time, domestic content ratio, single source and preferred supplier information. Its status moves between UNDER_EVALUATION → CONDITIONAL/APPROVED → DISQUALIFIED.
• PPAP level (1–5) — determines which elements are mandatory: Level 1 only the PSW (element 18), Level 2 the PSW plus dimensional/test/Cpk data (9, 10, 11, 18), Levels 3–5 cover all 18 elements.
• The 18 PPAP elements — Design Records, Authorised Engineering Change Documents, Customer Engineering Approval, DFMEA, Process Flow Diagram, PFMEA, Control Plan, MSA, Dimensional Results, Material/Performance Test Results, Initial Process Studies (Cpk), Qualified Laboratory Documentation, Appearance Approval Report (AAR), Sample Production Parts, Master Sample, Checking Aids, Customer-Specific Requirements, Part Submission Warrant (PSW).
• Scorecard — an IATF 16949 compliant weighted score: Quality 40% (penalised by PPM), On-time Delivery 30%, Documentation 15%, Responsiveness 15% (if an optional audit score exists, it replaces 15% of the total); it produces an A/B/C/D grade.
• FAI (First Article Inspection) — the first article inspection record; available at API level (see Constraints).

Typical Workflow

1. Open PPAP & AVL from the left-hand menu and create an AVL record with the part, supplier and commercial details from the New Supplier tab.
2. On the AVL record, mark the PPAP requirement and its level (1–5).
3. On the PPAP tab, see the element list generated automatically for that level; update each element with its owner, document reference and (where relevant) Cpk value.
4. When all mandatory elements are complete, the submission automatically moves to "Submitted to Customer".
5. Record the customer decision (Approved / Interim Approval / Rejected) — the AVL record status and the PPAP status synchronise automatically.
6. From the Scorecard tab, calculate period-based supplier performance (PPM, on-time delivery, documentation, responsiveness, audit) and track the A–D grade.
7. Use the Dashboard to monitor total AVL count, single-source parts, expiring approvals and pending PPAPs.

Feature Reference

• AVL CRUD and status transitions (Approved / Conditional / Disqualified), approval condition and validity date tracking
• Automatic generation of the 18-element PPAP package according to level
• Per-element status, document reference, Cpk value, sample size and owner tracking; automatic "submitted to customer" transition once all mandatory elements are ready
• PPAP readiness percentage and missing/rejected element report (ppap/{id}/readiness)
• Customer decision recording (Approve / Interim Approval / Reject) and automatic reflection onto the AVL
• IATF 16949 weighted supplier scorecard (Quality/Delivery/Documentation/Responsiveness/Audit) and A–D grading
• Dashboard: status distribution, single-source parts, expiring approvals, pending PPAP count, preferred suppliers
• FAI (first article inspection) record creation with automatic PASS/PARTIAL_PASS/FAIL result (at API level)

Constraints / Known Limits

• A backend API exists for FAI records but there is no dedicated tab in the interface yet; this flow is currently usable only for integration/automation scenarios.
• Data is held in an in-memory store for demo purposes; production requires a persistent database and tenant isolation.
• Scorecard calculation relies on manually entered PPM/delivery/documentation/responsiveness data; an automatic feed from the ERP/quality system is on the roadmap.