PPAP vs FAI for Molded Parts
FAI Measures the Part, PPAP Qualifies the Process
PPAP vs FAI is a scope choice, not a synonym. FAI measures first representative parts against the released drawing. PPAP adds process evidence only when your RFQ lists those documents. Write the deliverables by name. Do not paste PPAP Level 3 with an empty notes field.
Read first article inspection for injection molding for the drawing-report definition. Read what PPAP means for the short process-package definition. This page is the RFQ choice.
FAI = ballooned drawing + measured results
FAI proves the part. PPAP, when scoped, proves the process behind it. FAI asks whether this part matches this drawing revision. Incoming files balloon results. T1 samples vs FAI answers when first shots exist. FAI answers what was measured.
PPAP = FAI plus process documents when the customer requires them
PPAP is a broader approval package used when the RFQ asks for process evidence beyond that report. They are not two names for the same form. A PPAP usually includes dimensional results. It is not automatic on every molding quote.
ISO 9001 is the system mention, not a PPAP level
ISO 9001 certifies the system. It does not auto-generate a PPAP binder. ISO 9001 is the approved mention on molded part quality assurance. This page does not invent a PPAP level. It does not publish a capability number.
Not every NetProto program requires PPAP unless the RFQ defines that package. Many housings close on a visual check or an FAI. If your customer requires a broader set of documents, list those documents. A PPAP level number with no element list is a blank checkbox.
A worked example: incoming will file five balloon results and a material identity sheet. That is FAI plus material identity. Writing PPAP Level 3 because a previous metal part used it creates a document hunt that nobody scoped. Write the two deliverables.
What to tell sourcing: if the customer said PPAP, ask which documents they will file. If they only file a drawing report, write FAI. Upload CAD through the injection molding instant quote platform with that choice.
How to Route the Quality Word
Only need drawing conformance: write FAI report
If incoming only files balloon results, write FAI report and attach the print. Read specify inspection requirements on an RFQ for balloons, visual versus dimensional, and the revision pair. Do not add a broader package you will not use.
Customer sent a PPAP spec: list the elements you will file
Quality forwards a customer spec that says PPAP. Engineering only has a ballooned print. Write FAI report on named balloons plus the extra documents the spec actually lists. They do not type a level. The spec is input. The list is the RFQ.
Unsure: start with FAI on named balloons, scope up later
If you are unsure, write FAI on named features first. Add PPAP elements only when your customer requires them. A second check before you type either word: who files the paper, and on which drawing revision. If sourcing cannot name the recipient or the revision, write visual plus named mates until those two answers exist.
A level number with no list is not a package
A level number is a shorthand inside one customer's procedure. It is not a universal SKU. This page will not invent the contents of a level. If you write a number with no list, review still does not know which sheets you will file.
Common mistakes: treating PPAP and FAI as synonyms; pasting a level number with no element list; copying a competitor comparison table into the notes; asking the quote to inherit a package from another commodity.
What to tell sourcing: open the FAI article and the PPAP glossary, then write the deliverables. If they cannot name a deliverable, they are not ready to type PPAP.
What to Write Instead of PPAP
Named deliverables: FAI + material identity + process docs
Write the sheets you will file, not the acronym you heard last year. Name ballooned FAI, material identity, or a broader package your quality plan already lists. Start with the drawing report if that is the real need. Add material identity if incoming checks the named grade.
Revision pair still required (CAD = drawing)
A broader package still sits on a matching print and solid. Attach the drawing revision that matches the CAD. If they disagree, fix the pair before you name PPAP. See what to upload for a molding quote for the file set.
Capability discussion goes to sales, not the quote form
Sales can take certification paperwork that is not a marketing claim. Do not ask the quote form to display labels this site does not claim. Do not put a capability target in the notes as a substitute for balloons. Balloons come first. A process-capability talk follows with sales if the customer requires it.
Do not inherit a metal or automotive checklist the program will not use
Do not paste a 20-line automotive checklist that names documents you will not collect. Do not inherit a metal-part procedure because last year's supplier used it. Molding notes belong on this upload. Design for manufacturing flags can become named features later. They are not a PPAP binder.
A worked note: FAI report on Balloons 4, 5, 12, 18. Material identity to the named resin. Process discussion to follow with sales if the customer requires it. No level number. That note can be reviewed.
What to tell sourcing: if they are unsure, buy FAI on named features. Add documents later as a scoped change. Do not over-declare a package you cannot list.
RFQ Checklist
Use this list so the quality word matches the files.
- Choose FAI report, visual plus named mates, or a named PPAP package.
- Attach the drawing revision that matches CAD.
- List elements you actually need. Do not paste a level number with no list.
- Upload CAD through the injection molding instant quote platform.
Step 1 is the choice. Pick one primary ask. You can stack a visual note on an FAI. You cannot stack two undefined acronyms.
Step 2 is the revision pair. A broader package still sits on a matching print and solid. If they disagree, fix the pair before you name PPAP.
Step 3 is the element list. Write the sheets. If you cannot write them, you are not asking for PPAP yet.
Step 4 writes the choice onto the quote. A customer forward is not the RFQ until the files are attached.
A worked submit block: CAD Rev C, drawing Rev C. FAI report on five balloons. Material identity to named ABS. ISO 9001. Customer also asked for a process package: list attached. That block is usable. PPAP TBD is not.
Common mistakes at submit:
- Title bar PPAP, empty notes.
- FAI and PPAP with no balloons.
- Attaching a spec and calling it the list.
- Writing a level number with no element list.
- Using a capability target as a substitute for balloons.
What to tell sourcing: send this checklist with the CAD. Hold the quote as quality-scoped only after the word and the files agree.
What to tell quality: FAI is the drawing report. PPAP is the broader package only when the RFQ names the documents. ISO 9001 is the system mention. A level number is not a package.