PPAP Guide for US Manufacturers
Sourcing from Vietnam
Production Part Approval Process — all 18 elements, AIAG submission levels 1–5, and how Dewin manages PPAP documentation for Vietnam-made parts at $0 Section 301 tariff.
What Is PPAP?
Production Part Approval Process (PPAP) is a standardized quality documentation framework defined by the Automotive Industry Action Group (AIAG). It gives customers documented proof that a supplier can consistently manufacture parts to engineering specifications before full production begins.
Originally developed for the automotive supply chain (Ford, GM, Stellantis), PPAP has been widely adopted in industrial machinery, medical devices, aerospace, and consumer electronics — any industry where part quality consistency is critical.
For US buyers switching production from China to Vietnam, PPAP serves a dual purpose: it verifies the new supplier's process capability and provides the origin documentation trail needed for Section 301 tariff compliance.
Why PPAP Matters for Overseas Sourcing
- ✓ Confirms the supplier's process — not just their samples — can hit your specs
- ✓ Establishes a quality baseline before mass production
- ✓ Provides documented evidence for your internal supplier qualification
- ✓ Creates the paper trail for country-of-origin verification
- ✓ Reduces risk of receiving non-conforming parts at scale
- ✓ Required by most Tier 1 and OEM supplier quality manuals
PPAP Submission Levels 1–5
AIAG defines five submission levels. The customer specifies which level is required. Level 3 is the industry standard for new supplier relationships.
PSW Only
Part Submission Warrant only, no supporting documentation submitted to customer.
When to use: Established supplier relationships, non-critical commercial parts, repeat reorders.
PSW + Limited Documents
PSW plus product samples and a subset of supporting documentation.
When to use: Moderate-risk parts, existing supplier new part number.
PSW + Full Package
Complete PPAP package submitted to the customer for review and approval.
When to use: Most new supplier relationships. Industry standard starting point for new overseas suppliers.
PSW + Customer-Specific
Customer defines specific elements required beyond the standard package.
When to use: Customers with unique quality requirements, aerospace/defense applications.
Full Package at Supplier
Complete package reviewed at the supplier's manufacturing location.
When to use: Safety-critical parts, automotive Tier 1 supply, first-article at factory.
All 18 PPAP Elements
A complete Level 3 PPAP package contains all 18 elements below. Dewin's team reviews each element at the Vietnam factory before submitting to you.
Design Records
Engineering drawings, CAD data, and design specifications that define the part.
Engineering Change Documents
Documentation of any engineering changes with authorization.
Customer Engineering Approval
Signed approval from customer engineering for design deviations or concessions.
Design FMEA
Failure Mode and Effects Analysis covering design-level failure risks.
Process Flow Diagrams
Step-by-step manufacturing process from raw material to finished part.
Process FMEA
FMEA covering manufacturing process failure risks and detection methods.
Control Plan
Document listing all process controls: measurement systems, frequency, reaction plans.
Measurement System Analysis (MSA)
Gauge R&R and calibration studies proving measurement tools are capable.
Dimensional Results
Balloon drawing with all dimensions checked and recorded. Typically 5 initial samples.
Material / Performance Test Results
Material certificates (certs of conformance), hardness, tensile, or functional test data.
Initial Process Studies
Process capability (Cpk, Ppk) studies on critical characteristics. Cpk ≥ 1.67 preferred.
Qualified Laboratory Documentation
Proof that test labs are accredited (ISO 17025 or equivalent).
Appearance Approval Report (AAR)
For visible parts: color, gloss, surface texture sign-off with customer.
Sample Production Parts
Physical parts produced from the production process (not prototype tooling).
Master Sample
A retained reference part signed off by customer and supplier.
Checking Aids
Any fixtures, gauges, or templates used for inspection — documented and approved.
Customer-Specific Requirements
Any additional requirements from the customer's supplier quality manual.
Part Submission Warrant (PSW)
The summary document — signed by both parties — that formally approves the part for production.
PPAP + Tariff Savings by Process
Moving each process from China to Vietnam eliminates Section 301 tariffs — and requires a new PPAP submission. Dewin manages both.
| Process | HTS Chapter | China Tariff | Vietnam Tariff | PPAP Key Documents |
|---|---|---|---|---|
| CNC Machined Parts | 8466.93 / 8466.94 | 25% | $0 | Full dimensional results (CMM/VMM), material certs, process capability |
| Aluminum Die Castings | 7616.99 | 25% | $0 | Die casting process FMEA, metallurgy cert, dimensional report |
| Injection Molded Plastics | 3926.90 | 25% | $0 | Mold flow data, material certification, AAR (if visible), Cpk study |
| Steel Stampings | 7326.20 | 25% | $0 | Tooling FMEA, dimensional results, material cert (mill cert), Cpk on critical dims |
| Electronic Assemblies | 8536.50 | 25–145% | $0 | Component traceability, IPC workmanship, functional test records |
| Forged Parts | 7326.11 / 8483.10 | 25% | $0 | Die design review, heat treatment certs, mechanical properties testing, Cpk |
Tariff rates reflect Section 301 (China-specific) under the Trade Act of 1974. Vietnam-origin goods are not subject to Section 301. Verify current rates at USTR.gov.
How Dewin Manages PPAP for Vietnam Suppliers
Our on-the-ground team in Vietnam handles the full PPAP process — so you get documentation-ready parts without having to chase a factory overseas.
PPAP-Capable Factory Matching
Dewin matches your parts to Vietnam factories that have PPAP experience — particularly those supplying automotive Tier 1/2 manufacturers. We verify PPAP capability during our 50-point Dolphin audit.
Documentation Management
Our on-the-ground team in Vietnam reviews and compiles PPAP packages — dimensional results, material certs, process flow, FMEA, control plan — before submission to you. No chasing suppliers for paperwork.
First Article Inspection (FAI)
We run balloon drawings against first-article samples at the factory. CMM or 2D VMM dimensional results are captured on-site and included in your PPAP package.
Country-of-Origin Documentation
Every PPAP package includes Vietnam origin documentation — manufacturer declarations and Certificate of Origin. Critical for Section 301 tariff compliance: proves your parts are Vietnam-origin, $0 tariff.
Tariff Change Trigger Response
Moving production from China to Vietnam triggers a PPAP re-submission requirement. Dewin manages the full new-supplier PPAP as part of your China+1 transition — no gaps in documentation.
Ongoing PPAP Maintenance
Any engineering change, tooling repair, or process change at the factory triggers a PPAP update (ECN). Dewin monitors factory changes and initiates re-approval when required — protecting your supply chain from silent quality drift.
PPAP + Dolphin Audit: Two Layers of Confidence
Dewin's 50-point Dolphin Audit assesses the factory's baseline capability. PPAP documents that a specific part has been approved for production. Together, they give you maximum confidence before committing to volume production.
50-Point Dolphin Audit
- ✓ Factory-level assessment (equipment, processes, quality systems)
- ✓ 5 pillars: Equipment, Quality, Management, Capacity, Compliance
- ✓ On-site visit with real photos and video evidence
- ✓ QCLDM score out of 100 (≥70 required to enter Dewin network)
- ✓ Applied to all 179+ factories before they enter our network
PPAP Documentation
- ✓ Part-specific approval (this exact part, this exact factory, this exact process)
- ✓ 18 elements: dimensional results, material certs, FMEA, control plan, PSW
- ✓ Process capability data (Cpk, Ppk) on critical characteristics
- ✓ Managed by Dewin's on-ground team at the Vietnam factory
- ✓ Includes Vietnam country-of-origin documentation (CO + manufacturer declaration)
PPAP FAQ
What is PPAP and why does it matter for overseas sourcing?
PPAP (Production Part Approval Process) is an AIAG-standardized process that verifies a supplier can consistently manufacture a part to your engineering specifications. For overseas sourcing, PPAP is critical because it provides documented evidence — dimensional reports, material certs, process capability studies — that a new factory can hit your specs before full production begins. It dramatically reduces the risk of receiving non-conforming parts at scale.
Can Vietnam factories provide PPAP documentation?
Yes. The best Vietnamese factories — particularly those supplying automotive Tier 1 and Tier 2 manufacturers — produce full PPAP packages including dimensional results, material certifications, process flow diagrams, FMEAs, control plans, and PSW. Dewin's 179+ audited factory network includes factories with PPAP experience. Our team manages the documentation process and reviews every package before it reaches you.
What PPAP level should I require from a new Vietnam supplier?
For a new overseas supplier relationship, Level 3 PPAP is the most common starting point — it requires the full package to be submitted to the customer. For critical automotive or safety parts, some customers require Level 4 (specific items defined by customer) or Level 5 (reviewed at supplier location). For non-critical commercial parts from a qualified, audited supplier, Level 1 (PSW only, no documentation submission) may be acceptable for reorders.
How does moving production from China to Vietnam affect PPAP?
Any change in manufacturing location — including moving from China to Vietnam — typically triggers a new PPAP requirement. This is because PPAP is process- and facility-specific: it documents that a specific factory with specific equipment can consistently make your part. Dewin manages this PPAP re-submission as part of the supplier transition process, ensuring full documentation is in place before production begins.
Does sourcing from Vietnam affect PPAP tariff compliance?
Yes — and positively. Vietnam-origin parts are not subject to Section 301 tariffs (China-specific under the Trade Act of 1974). A PPAP from a Vietnamese supplier includes country-of-origin documentation that supports your customs compliance and demonstrates genuine manufacturing in Vietnam — critical for avoiding tariff reclassification risk.
Ready to Source from Vietnam with Full PPAP Documentation?
Dewin manages PPAP for 179+ audited Vietnam factories — plus $0 Section 301 tariffs on every part. Get a quote and we'll confirm PPAP capability for your process.