The Appearance Approval Report (AAR) is a required element of the PPAP submission for parts where appearance is a critical requirement. It provides documented evidence that the product meets the customer’s visual, cosmetic, and surface quality expectations.
The AAR is generated as part of the Appearance Approval Inspection (AAI) process and must be formally approved before production parts are released.
What the AAR includes
The Appearance Approval Report should document:
- The part number and revision level
- The appearance inspection criteria and acceptance standards
- Evaluation results for visual and cosmetic characteristics
- Any identified concerns, deviations, or conditions of approval
All relevant supporting documents, such as photographs, samples, or inspection notes, should be included where applicable.
Customer approval and sign-off
The AAR must be:
- Reviewed and signed by the customer or an authorised representative
- Approved prior to, or as part of, the PPAP submission
- Clearly traceable to the approved Design Record
Customer sign-off confirms that the appearance of the part is acceptable for production release.
Handling appearance concerns
If any appearance-related issues are identified:
- They must be clearly documented in the AAR
- Any approved deviations or temporary waivers must be referenced
- Ongoing controls should be reflected in the Control Plan
Unapproved appearance deviations are a common cause of PPAP delays or rejection.
Key considerations
- AAR is required only for parts with appearance requirements
- Evaluation must be performed on production-intent parts
- Appearance criteria should be clearly defined and agreed
- The AAR must align with customer-specific requirements
The Appearance Approval Report ensures that aesthetic expectations are met alongside functional and dimensional requirements.