Introduction

A major OEM faced delays in New Product Development (NPD) due to incomplete PPAP (Production Part Approval Process) submissions from Tier-1 and Tier-2 suppliers. With on-time PPAP completion rates as low as 30-40%, Catalydd intervened to streamline documentation, address skill gaps, and ensure compliance with OEM’s Level 3 PPAP requirements.

Challenges

• Pending PPAP Submissions: Critical documents delayed at NPD stage.
• OEM Requirements: Level 3 PPAP (PSW, product samples, supporting data) not met.
• Skill Shortages: Suppliers lacked expertise to prepare PPAP/Re-PPAP documentation.
• Low On-Time Completion: Only 30-40% of PPAPs submitted monthly met deadlines.

Project Milestones

1. Roadmap Development (Month 1): Collaborated with OEM to define PPAP completion targets.
2. Commodity-Specific Deployment (Month 1-2): Assigned expert engineers (Sheet Metal, Casting, Machining, etc.) to suppliers.
3. Execution & Review (Month 2-4): Weekly/Monthly progress tracking and issue resolution.
4. Final Submission (Month 5): Completed pending PPAPs and uploaded documents to OEM portals/SAP.

Our Solution

Catalydd’s multi-pronged approach included:

• Commodity Expertise: Deployed specialists for Sheet Metal, Casting, Machining, Hydraulics, and Surface Treatment to address technical gaps.
• Documentation Support:
  ● Prepared PSW (Part Submission Warrant), dimensional reports, and process flow diagrams.
  ● Compiled supporting data (material certifications, process validations).
• Training: Upskill supplier teams on PPAP requirements and portal submissions.
• Sustained Monitoring: Regular audits to ensure adherence to timelines and quality standards.

Results

1. 90% On-Time PPAP Completion: Surpassed OEM’s submission deadlines.
2. Reduced NPD Delays: Accelerated product launches by resolving documentation bottlenecks.
3. Supplier Empowerment: Enhanced in-house capability to manage future PPAP/Re-PPAP activities.