PPAP levels 1 to 5 explained: what each submission actually needs
When an automotive customer asks for a "Level 3 PPAP," they are telling you exactly how much evidence to submit with your parts. PPAP — the Production Part Approval Process from AIAG — has five submission levels, and getting the level wrong means either a rejected submission or weeks of wasted documentation. Here is what each of the PPAP levels 1 to 5 requires, in plain language.
What PPAP is (in one paragraph)
PPAP is the standard way a supplier proves to a customer that it understands the drawing and that its process reliably makes conforming parts. It is built from up to 18 elements — things like the design record, process flow diagram, PFMEA, control plan, dimensional results, material certs, MSA studies, capability studies, and the Part Submission Warrant (PSW). The submission level decides how many of those 18 elements you actually send to the customer versus retain on file.
The five submission levels
| Level | What you submit to the customer | Typical use |
|---|---|---|
| Level 1 | PSW only (plus appearance approval if applicable) | Low-risk, catalogue or standard parts |
| Level 2 | PSW + product samples + limited supporting data | Lower-risk parts where some evidence is wanted |
| Level 3 | PSW + samples + complete supporting data (all 18 elements as applicable) | The default for most new parts |
| Level 4 | PSW + whatever the customer specifically requires | Customer-defined, case by case |
| Level 5 | PSW + samples + full data reviewed at the supplier's site | High-risk / safety-critical, on-site review |
Level 3 is the one you will see most. When in doubt, assume Level 3 and confirm with the customer's supplier quality engineer.
The 18 elements at a glance
Design record · engineering change documents · customer engineering approval · DFMEA · process flow diagram · PFMEA · control plan · MSA studies · dimensional results · material/performance test results · initial process studies (Cp/Cpk) · qualified lab documentation · appearance approval report · sample parts · master sample · checking aids · customer-specific requirements · Part Submission Warrant (PSW).
Two of these trip up suppliers most: dimensional results (every characteristic measured against the drawing — which starts with ballooning) and initial process studies (capability evidence).
PPAP vs first article inspection
If you also work in aerospace, note that PPAP is the automotive cousin of AS9102 first article inspection — same goal, different framework and paperwork. We break down the differences in AS9102 vs PPAP: which standard does your customer need.
Where the time goes — and how to cut it
The dimensional-results element means numbering and measuring every characteristic on the drawing. Done by hand on a 150-characteristic part, that is most of a day. Auto-ballooning collapses it: CadNexa's Smart Detect places numbered balloons on detected dimensions and tolerances in under a minute, reads the values, and exports the characteristic list straight into your dimensional-results sheet. See the full workflow in ballooning and inspection reports in 10 minutes.
Build your PPAP dimensional results faster
Auto-balloon the drawing and export the characteristic list for your submission. Free, no install.
Try CadNexa Free →Frequently asked questions
What is the most common PPAP level?
Level 3 — full supporting data plus samples and the PSW — is the default for most new automotive parts. Always confirm with the customer.
What is the difference between Level 3 and Level 5?
Both require complete data. Level 3 is submitted to the customer; Level 5 is reviewed at your facility by the customer, typically for high-risk or safety-critical parts.
Do I still prepare all 18 elements for Level 1?
You prepare and retain the applicable elements on file, but you only submit the PSW (and appearance approval where relevant). The customer can request the rest.
Is PPAP the same as FAI?
No. PPAP is the AIAG automotive process; FAI (AS9102) is the aerospace equivalent. They share intent but differ in elements and forms.
How do I produce dimensional results quickly?
Balloon the drawing automatically, measure against each characteristic, and export — avoiding manual re-typing, the top source of errors.