PPAP deliverable guide

How to complete Process Flow Diagram

The process flow diagram shows the actual sequence used to receive, make, inspect, handle, package, store, and ship the product.

Complete the fields

Process step number
Give each meaningful operation a stable, unique number. Reuse it in the PFMEA and Control Plan.
Process step name
Use a clear operational name, such as “CNC drill,” “torque verification,” or “final pack.”
Inputs and outputs
Identify incoming material, components, information, or condition and the output passed to the next step.
Decision and nonconforming paths
Show inspection decisions, rework where permitted, segregation, scrap, and outsourced operations.
Equipment or location, if used
Identify the work center, machine family, or external process when it helps define the process boundary.

Step-by-step completion sequence

  1. Walk the real process from receiving to shipping with the people who operate and support it.
  2. Draw each operation, movement, inspection, storage, and external process in sequence.
  3. Add input/output and decision paths needed to understand product control.
  4. Align step names and numbers with PFMEA, Control Plan, work instructions, and operator records.
  5. Approve the flow and revise it under change control when the route changes.
PPAP control point: The customer’s current submission request, customer-specific requirements, and approved forms control. This guide explains a practical way to prepare the record; it does not authorize a substitute format or acceptance criterion.