Wind Energy
    PPAP/APQP
    Featured

    PPAP Quality Turnaround: From 142 Issues to 5

    January 13, 2025
    8 min read
    By Qualiteh Team

    At a Glance

    Duration7 Production Batches (~4 months)
    Team RoleQuality & Documentation Lead
    PPAP issue reduction
    96.5%(from 142 to 5 issues)

    The Challenge

    At the start of a major wind turbine component program, PPAP (Production Part Approval Process) submissions were creating a bottleneck that threatened the entire program timeline. Each submission cycle generated excessive rework, extended feedback loops, and frustrated both internal teams and suppliers.

    The root causes weren't product-performance issues. They were preventable documentation and consistency gaps: the kind of problems that seem minor individually but compound into major delays when multiplied across dozens of components and suppliers.

    Specific Problems

    142 issues in first batch
    Set negative baseline, created immediate backlog — 142 issues
    Repeated resubmissions
    Each cycle added 1-2 weeks to approval timeline
    Inconsistent review criteria
    Different reviewers flagging different issues
    No supplier pre-check process
    Errors discovered only during formal review
    Late-stage discoveries
    Risk of finding gaps close to production release

    Business Impact

    With multiple suppliers and components in the pipeline, the cumulative effect was severe: • Program timeline at risk – Each resubmission cycle added 1-2 weeks • Engineering hours consumed – Teams spending more time on paperwork than problem-solving • Supplier relationships strained – Unclear expectations creating friction • Launch date pressure – Customer commitments dependent on approval timeline

    The Approach

    Methodology: PPAP/APQP
    1

    Batch-Based Progress Tracking

    Objective: Create visibility into system health and improvement trends

    Rather than treating each PPAP as an isolated event, we implemented batch-level issue tracking as a leading indicator.

    Actions:
    • Counted issues per batch to establish baseline (Batch 1: 142)
    • Categorized issues by type to identify patterns
    • Created trend visibility for stakeholders
    • Enabled objective measurement of improvement efforts
    Deliverable:
    Issue tracking dashboard showing batch-by-batch trends
    2

    Standard PPAP Verification Checklist

    Objective: Ensure consistent, complete reviews across all reviewers

    The lack of standardized acceptance criteria meant different reviewers were flagging different issues, creating confusion and rework. We developed a comprehensive PPAP checklist.

    Actions:
    • Same checklist for every reviewer (eliminated inconsistent criteria)
    • Complete verification every time (no missed items)
    • Faster, structured reviews (improved cycle time)
    • Clear, actionable findings (better supplier feedback)
    Deliverable:
    Internal PPAP verification checklist (comprehensive, reusable)
    3

    Supplier Pre-Submission Checklist

    Objective: Shift error detection earlier in the process

    The same checklist used internally was shared with suppliers before they submitted their PPAP packages.

    Actions:
    • Shared expectations: Suppliers knew exactly what would be checked
    • Self-verification: Suppliers could catch issues before formal review
    • Reduced resubmissions: Errors fixed before they became formal findings
    • Capability building: Suppliers improved for future programs
    Deliverable:
    Supplier pre-check checklist (aligned with internal verification)

    The Results

    Issues per batch

    Before
    142
    After
    5
    96.5% reduction

    Review cycles per PPAP

    Before
    3-4
    After
    1-2
    50%+ faster

    Time spent on rework

    Before
    High
    After
    Minimal
    60%+ reduction

    Business Impact

    • Faster PPAP approvals: reduced cycles from 3-4 to 1-2
    • Reduced operational overhead: 60%+ less time on rework
    • Improved supplier relationships: clear expectations
    • Program timeline protected: eliminated bottleneck

    Most Frequent Issue Categories

    1. Missing/incorrect CNs and part identifiers
    high frequency
    Root cause: Data entry gaps
    2. Missing signatures and approvals
    high frequency
    Root cause: Process not followed
    3. Missing Control Plan, PFMEA, Process Flow
    medium frequency
    Root cause: Incomplete packages
    4. Missing NDT, coating, corrosion evidence
    medium frequency
    Root cause: Documentation gaps
    5. Dimensional reports missing IDs/tolerances
    medium frequency
    Root cause: Template issues

    Key Insights

    •Patterns Identified

    • •Most issues are preventable: Documentation gaps, not technical problems
    • •Consistency drives improvement: Same checklist = same standards
    • •Supplier enablement works: Shifting left reduces rework
    • •Trends reveal system health: Batch tracking enables prediction

    Critical Success Factors

    • One clear checklist: Eliminated ambiguity in expectations
    • Shared with suppliers: Alignment before submission
    • Continuous tracking: Made improvement visible and measurable
    • Management support: Resources for process development
    "

    Key Takeaway

    The biggest leverage comes from having one clear PPAP checklist, shared expectations with suppliers, and continuous issue trend tracking. Most PPAP problems aren't technical; they're process gaps that can be eliminated with structured review.

    Deliverables

    ✅ PPAP issue tracking system
    Batch-by-batch visibility
    Applicable to future programs
    ✅ Internal PPAP verification checklist
    Consistent, complete reviews
    Standardized for all reviewers
    ✅ Supplier pre-check checklist
    Error prevention at source
    Shared with all suppliers
    ✅ Repeatable PPAP review workflow
    Structured process
    Institutionalized
    ✅ Issue categorization taxonomy
    Pattern recognition
    Enables trend analysis

    Client Perspective

    "Before this engagement, PPAP was our bottleneck. Every submission felt like a coin flip: would it pass or bounce back with a dozen new findings? Now we have a repeatable process. Suppliers know what we expect, reviewers know what to check, and we can actually see our improvement over time."

    — Quality Lead
    Wind Energy Component Manufacturer

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