Within the Production Part Approval Process (PPAP), Design Records define the approved design intent for a part and serve as the foundation for all validation and inspection activities. In most cases, these records are provided by the customer, as they are responsible for the original design and fully understand the part’s function and end use.
Design Records typically consist of engineering drawings, CAD models, specifications, and associated notes that describe how the part must be manufactured, inspected, and verified.
Why Design Records are required in PPAP
A copy of the Design Record must be included with the PPAP submission for several critical reasons:
- Confirms design alignment
Demonstrates to the customer that the supplier is working to the correct and current part definition. - Verifies drawing revision control
Confirms that both supplier and customer are referencing the same drawing version and revision level. - Prevents miscommunication
Ensures that all discussions, inspections, and approvals relate to the same part and design intent.
Without clearly defined Design Records, accurate inspection results, risk analysis, and process validation are not possible.
Ballooning and traceability
All Design Records included in a PPAP submission should be fully ballooned (or road-mapped). Each ballooned characteristic must directly correspond to inspection and test results included elsewhere in the PPAP package.
This includes:
- All dimensional features
- Print notes and general tolerances
- Material, coating, and finish requirements
- Special characteristics and symbols
- Any other specifications relevant to the design
Ballooning ensures full traceability between the design requirements and the evidence proving compliance.
Supporting specifications
In addition to drawings, Design Records may also include:
- Functional requirements
- Material and performance specifications
- Test and validation requirements defined by the customer
These documents form part of the approved design definition and must be referenced, controlled, and validated as part of the PPAP submission.
Key considerations
- Design Records must reflect the latest approved revision
- Any changes require authorised engineering change documentation
- All downstream PPAP elements (DFMEA, PFMEA, Control Plan, inspection results) must align with the Design Record
Design Records are the cornerstone of PPAP. If the design definition is incorrect, incomplete, or uncontrolled, the entire approval package is compromised.