Engineering · Manufacturing · PPAP Handbook

PPAP Authorized Engineering Changes and Customer Engineering Approval

How to control engineering deviations, unincorporated changes, approvals, waivers and internal process interpretations within a PPAP submission.

Handbook chapter
~7 min read
Source pages 2-2
6 source assessment prompts
Dark / light theme ready

CategoryEngineering / Manufacturing

SourcePPAP Submission Assessment

Document basisUploaded 15-page assessment

StatusPublication-ready handbook

Executive summary

The uploaded assessment distinguishes two related controls. First, any change incorporated into product, part or tooling but not yet reflected in the released design record needs authorized engineering change documentation; anything that varies from the design record requires written and approved deviation authorization. Second, formal customer engineering approval is expected unless an engineering waiver is documented. The handbook objective is to prevent a PPAP from appearing compliant only because the approved exception or customer consent is hidden outside the package.

01How to use this chapter

This chapter separates the uploaded assessment criteria from practical KEVOS implementation guidance. The section titled Source-derived assessment criteria preserves the intent, terminology and checklist detail supplied in the uploaded PPAP Assessment. The surrounding handbook guidance explains how a manufacturing or supplier-quality team can organise evidence, perform a readiness review and spot gaps before formal submission. Where the uploaded source states a numeric threshold, edition reference or customer-specific expectation, it is identified as source-derived rather than presented as a universal rule.

Use the chapter in three passes. First, read the purpose and workflow to understand what the element is meant to prove. Second, work through the source-derived prompts against the actual part number, engineering revision and production process. Third, close the red flags and collect objective evidence before the package is released. For large PPAPs, record the evidence location beside each source prompt so another reviewer can repeat the assessment without relying on verbal explanation.

02Handbook workflow

Identify every difference from the released design recordCompare the production condition with the drawing/specification baseline and list deviations, temporary changes and approved-but-not-yet-incorporated changes.
Verify the authorizationConfirm that the deviation or engineering-change record is complete and carries the approvals required by the Organization/customer process.
Define the boundary of the exceptionThe source expects practical limits such as number of pieces, time limit and forthcoming change information. A deviation should not become an open-ended substitute for a released design change.
Include engineering consent or waiverAttach the formal customer engineering approval or controlled engineering waiver where the Organization requires it.
Cascade the approved interpretationIf internal process instructions reinterpret or communicate design-record requirements to production, make sure those controlled instructions align with the approval and downstream control plan.
Close the loopWhen the permanent design record is updated, retire or disposition temporary deviation documents in accordance with document control.

03Evidence package to retain

The assessment is stronger when each conclusion points to a controlled record rather than a statement that the requirement is “covered”. The following evidence set is a practical minimum for this chapter; actual customer and contractual requirements govern the live submission.

Approved deviation or engineering-change document
Approval signatures/status
Quantity or time limits for temporary deviation
Reference to the future permanent change where applicable
Formal customer engineering approval
Controlled engineering waiver when approval is waived
Internal process instruction or controlled interpretation where used
Evidence of linkage to control plan/work instructions

04Source-derived assessment criteria

Source fidelity

The prompts below are taken from the uploaded 15-page PPAP Assessment and kept as assessment questions. The source uses the term “Organization” for the customer/receiving organisation in many places.

2.2.2 Authorized Engineering Change Documents

Authorized engineering change documents for those changes not yet recorded in the design record but incorporated in the product, part or tooling. Submissions shall include written and approved Deviation authorization for anything that varies from the Design Record.

1.If applicable is approved deviation attached?
2.Is deviation completely filled out?
3.Are proper approvals in place?
4.Does deviation clearly identify number of pieces, time limit, change forthcoming, ETC. information for proper PPAP disposition?

2.2.3 Customer Engineering Approval

Organization requires formal engineering approval unless engineering waiver documented and in place. Include any supporting documentation that formalizes Organization’s consent to the design (i.e. application checklist, functional specification, etc.) Include Internal (suppliers) documents that re-interpret Design Records, including Process Instruction sheets used to communication the Design Record data throughout the process. (see Control Plan and addendum for Process Instructions)

1.Formal controlled document for “Customer Engineering Approval”.
2.Formal controlled document of engineering waiver.

05Common red flags

These are practical review signals derived from the relationships and controls repeatedly required by the source. A red flag does not automatically mean the submission must be rejected; it means the condition deserves documented resolution before approval.

Production condition differs from drawing but no deviation is attached
Deviation is unsigned, expired or does not define its limits
Customer approval is assumed from email conversation but no controlled approval exists
Process instructions contain an interpretation that conflicts with the design record
Temporary deviation remains active with no path to permanent change
A waiver exists but its scope does not cover the submitted part or condition

06Cross-document interfaces

PPAP elements should not be reviewed as isolated files. Check the following interfaces for consistent part identity, revision, characteristic naming, operation numbering and control logic.

Interface