PPAP Dimensional Results Report: Format, Example, and How to Fill It

Direct answer: A PPAP dimensional results report is a structured table that lists every ballooned characteristic from the engineering drawing — balloon number, characteristic description, nominal value, upper and lower tolerance limits, actual measured value for each sampled part, and an I (in tolerance) or D (deviation) disposition. It is a mandatory element of the Production Part Approval Process (PPAP) package as defined by the AIAG PPAP 4th Edition reference manual.

When the Format Matters More Than You Expect

A dimensional layout report submitted with mismatched balloon numbers, missing GD&T callouts, or tolerance limits copied incorrectly from the drawing will trigger an immediate rejection — not because the parts are bad, but because the paperwork does not match the drawing. Customers such as OEM tier-1 programmes often return the entire PPAP package for resubmission, adding weeks to a launch timeline.

The format looks deceptively simple: a spreadsheet with columns and rows. The difficulty is in the accuracy of transcription, the completeness of characteristics captured, and the correctness of tolerances entered. Getting it right the first time saves significant rework for both supplier and customer quality teams.

What Is at Stake for Quality Engineers

An incorrect or incomplete dimensional results section delays Part Submission Warrant (PSW) approval, holds up production purchase orders, and can trigger an escalation to a supplier quality engineer visit. Beyond the launch risk, errors in the report create audit findings under IATF 16949 Clause 8.3.4 and PPAP requirements, which feed directly into your supplier scorecard. The format is not bureaucracy — it is the evidence trail that your process is capable of holding print dimensions in production.

The PPAP Dimensional Results Report Format: Column by Column

The AIAG PPAP 4th Edition (aiag.org) does not prescribe a single locked template, but it specifies the data elements that must be present. Most customers provide their own Excel template; the columns below represent the universal standard that satisfies all common variants.

A common customer-specific addition is a "Special Characteristic" column flagged with △ (Safety) or ✦ (Critical) symbols per IATF 16949 and customer-specific requirements. Always check the customer PPAP manual before finalising your template layout.

How to Fill a PPAP Dimensional Results Report: Step-by-Step

1. Obtain the correct drawing revision. Confirm the drawing number, revision level, and date with the customer purchase order and PSW. Using a superseded revision is the single most common reason for immediate PPAP rejection.
2. Balloon the drawing. Assign a sequential balloon number to every dimension, GD&T callout, surface finish, thread specification, and reference note that requires inspection. Do not skip general tolerances — they must appear in the report or be explicitly excluded by customer agreement. For a detailed guide on the ballooning process, see What Is Ballooning a Drawing? Meaning and Guide.
3. Populate the nominal and tolerance columns. Transcribe nominals and tolerances directly from the drawing. For dimensions governed by ISO 2768 (iso.org) general tolerances, expand the class tolerance to its absolute UTL/LTL values so the inspector does not need to look up the table. For example, a 25 mm dimension under ISO 2768-m carries ±0.20 mm, so UTL = 25.200 mm and LTL = 24.800 mm.
4. Record the gauge / instrument reference. Add a header row or footer note listing the calibrated instrument used for each characteristic type — CMM, micrometer, plug gauge, surface roughness tester. Include gauge ID and calibration due date. This satisfies IATF 16949 Clause 7.1.5.1.
5. Enter measured values for each sample part. AIAG PPAP requires a minimum of one full dimensional layout. Most customers require five parts minimum; tier-1 programmes often specify thirty. Enter the raw measured value — never round to fit within tolerance.
6. Calculate the I/D disposition for every cell. A simple Excel IF formula works: =IF(AND(B2>=LTL, B2<=UTL),"I","D"). Highlight D cells in red using conditional formatting so they are immediately visible to the customer reviewer.
7. Handle deviations before submission. Each D result must carry a written disposition in the Remarks column — either a customer-approved deviation number, a corrective action plan reference, or confirmation of a scrapped sample. Never submit a PPAP with unexplained D results.
8. Add the header block. Every PPAP dimensional results report must carry: part name, part number, drawing revision, supplier name, supplier DUNS or code, date of measurement, engineer name and signature, and PPAP submission level. Missing any one of these fields will cause a return for resubmission.
9. Attach the ballooned drawing. The dimensional results report is always submitted alongside the ballooned print so the customer can cross-reference every balloon number without ambiguity. Both documents form a single traceable package.
10. Review against customer-specific requirements (CSRs). Ford, GM, Stellantis, and BMW all publish CSRs that override AIAG defaults on column naming, number of samples, and electronic submission format. Check the relevant CSR before finalising.

Worked Example: Aluminium Bracket, 5-Part Layout

Consider a simple machined aluminium bracket (Al 6061-T6) with four dimensions to illustrate how the table looks when populated with real numbers. The drawing specifies one bore diameter, one overall length, one true position callout per ASME Y14.5-2018, and one surface finish.

*Balloon 3, Part 3: True position measured at ⌀0.211 mm against a tolerance of ⌀0.200 mm. Remarks column must reference a customer deviation (e.g. DEV-2024-0047) or a corrective action. The remaining four parts conform. This single out-of-tolerance result prevents PSW approval until dispositioning is complete.

Note: true position is always a diameter zone value (⌀), never a ± value. Entering it as ±0.100 mm is a common error that changes the tolerance zone shape entirely and contradicts ASME Y14.5-2018 Section 9. See GD&T True Position Formula with Worked Example for the full calculation method.

PPAP Dimensional Layout Report Template: What a Good Header Looks Like

The header block of a dimensional results report is as important as the data table. A complete header for a PPAP Level 3 submission contains the fields shown below.

Missing the instrument calibration due date is an IATF 16949 audit nonconformance waiting to happen. Reviewers at major OEMs are trained specifically to look for it.

Common Mistakes and Pitfalls

Skipping general tolerance dimensions. Engineers frequently balloon only the explicitly toleranced dimensions and omit anything governed by the title block general tolerance (ISO 2768 or ASME Y14.5 general notes). Customers expect every dimension on the drawing — including general tolerance ones — to appear in the report or be explicitly excluded by written agreement.

Rounding measured values to show conformance. Entering 25.025 when the CMM reads 25.026 is falsification of quality records. It voids the PPAP, triggers a potential containment action, and is an IATF 16949 fraud finding. Always record the raw instrument reading, then let the I/D formula decide conformance.

Mismatching balloon numbers between the drawing and the report. If the drawing has balloon 17 pointing to a thread callout and the report has balloon 17 labelled as a radius, the customer reviewer cannot cross-reference. This is usually caught immediately and results in resubmission. Re-ballot the drawing from scratch if you discover mismatches rather than trying to patch individual rows.

Using asymmetric tolerance values incorrectly. A dimension of 50.000 +0.050/−0.020 has UTL = 50.050 and LTL = 49.980. Entering ±0.035 (the average) is wrong and changes the acceptance boundary by up to 15 µm. Always split asymmetric tolerances into their explicit UTL and LTL absolute values.

Omitting GD&T datums from the characteristic list. Datum feature controls such as flatness on datum A or perpendicularity of datum B relative to A are inspectable characteristics and must be ballooned and reported. Many quality engineers assume datums are reference-only and skip them entirely.

Not cross-linking to the MSA / Gauge R&R study. The dimensional results are only as trustworthy as the measurement system. AIAG PPAP requires an MSA study for all gauges used on special characteristics (AIAG MSA 4th Edition). Reference the gauge R&R document number in your remarks header so the reviewer can pull both documents together. See also How to Do a Gauge R&R Study for Inspection.

How CadNexa Helps

Manually transcribing balloon numbers and tolerance data from a PDF drawing into an Excel dimensional results template takes hours and introduces transcription errors at every step. CadNexa's FAI Report Generator is live and supports the PPAP format alongside AS9102 Rev C, ISO, ASME, DIN, JIS, GB, and IS formats.

The workflow is straightforward: use the Box+Balloon OCR feature to draw a box around any dimension on the drawing — it reads the value, tolerance, and characteristic type (diameter, radius, thread, GD&T) and pre-fills the balloon data automatically. Smart Detect Dimensions can scan the entire drawing in one click to auto-detect all dimensions and GD&T frames for review. Once all balloons are confirmed, the FAI Report Generator outputs the dimensional results report as an interactive HTML, PDF, or CSV file — with balloon numbers, nominals, tolerances, and characteristic descriptions already populated. You add the measured values; CadNexa handles the structure. Try it at cadnexa.com/app.html. The CSV export is particularly useful if your customer requires data import into their own supplier portal.

For background on how ballooning feeds directly into PPAP documentation, see PPAP Levels 1 to 5 Explained: What Each Needs and PPAP Level 3 Submission Requirements Explained.

Frequently Asked Questions

What is the PPAP dimensional results report?

It is a document within the Production Part Approval Process (PPAP) package that records the actual measured values for every ballooned characteristic on an engineering drawing, compared against the nominal and tolerance values. It demonstrates to the customer that the production process consistently meets print requirements across all sampled parts.

How many parts must be measured for a PPAP dimensional layout?

AIAG PPAP 4th Edition requires a minimum of one part to be fully dimensionally laid out — all characteristics measured. Many customers specify five to thirty parts so statistical spread can be assessed. Always check the customer-specific requirements and the relevant CSR before determining your sample size.

What does 'I/D' mean in the dimensional results section?

'I' means the characteristic is In tolerance (conforming). 'D' means Deviation — the measurement falls outside the specified tolerance. A D result requires a written disposition such as a customer-approved deviation or waiver before the PPAP can be approved and the PSW signed.

Can I use Excel for the PPAP dimensional results report?

Yes, and most tier-2 suppliers still do. However, manually transcribing balloon numbers and tolerance data from a PDF drawing into Excel is slow and error-prone. Tools such as CadNexa extract dimension, tolerance, and GD&T data directly from the drawing via OCR and auto-generate the report structure, which significantly reduces preparation time and transcription risk.

Is the dimensional layout report required for all PPAP levels?

The dimensional results report is required at PPAP Levels 2, 3, 4, and 5. At Level 1, only a Part Submission Warrant (PSW) is submitted to the customer; no dimensional data accompanies it. However, the supplier must still retain the full dimensional layout on file, available for customer review on request.

Conclusion

The PPAP dimensional results report is not a checkbox exercise — it is the core evidence that your manufacturing process holds print dimensions in production. Getting the format right means correctly ballooning every characteristic, entering UTL and LTL as absolute values, recording raw measured data without rounding, and properly dispositioning every out-of-tolerance result before submission.

The fastest way to eliminate transcription errors between the drawing and the report is to let the software read the drawing for you. Try CadNexa's FAI Report Generator free — 14 days, no card required — at cadnexa.com/app.html. Your first PPAP dimensional results report can be structured and ready for measured data entry in minutes, not hours.