How to create a PPAP Dimensional Results Report

The PPAP (Production Part Approval Process) dimensional test results report provides a record of the dimensional data taken from product manufactured during the production run. A ballooned part drawing is required as part of the design record, and is referenced in the dimensional test results. The dimensional results report for element 9 must include:

• Dimensional results for each unique manufacturing process
• Actual measured results of all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record and Control Plan
• Design record that includes: change level, drawing date, organization name and part number. 
• Identify one of the measured parts as the master sample

Generally, these requirements are met by including a bubbled part drawing and a spreadsheet that includes all of the dimensions/specifications and the test results.

The AIAG PPAP Manual does not specify how many parts should be inspected. However, the industry standard we see is 6 pieces from the first lot. They do not need to be the first 6 pieces, and the master sample does not have to be the first one you produce. 

Below is an example of the Dimensional Test Results. It shows:

• Item number that corresponds to the part drawing
• Dimension/specifications, the specification/limits,
• Test date
• Quantity tested
• Results of the measured parts (in this case 6 parts were measured)
• Measurement results: whether the inspected parts are "OK" or "Not OK"

Depending on the requirements of your customer, you may not need all these fields, or additional fields may be required, such as testing more parts. 

Below is an example of the corresponding part drawing, which has each dimension ballooned.

Create PPAP Dimensional Results Reports with InspectionXpert

PPAP templates come with InspectionXpert and can be used to create your dimensional results report. These templates use Excel formulas to calculate whether entered measured results values fall within the acceptable range. Comparing the nominal value, upper limit and lower limit of each characteristic, against the measured values of the characteristic, and will automatically indicate "Ok" or "Not Ok" based on the calculations. Basic dimensions are automatically marked as “Ok”. Any characteristics that is a note will also be automatically marked as “Ok”. 

The template also contains a feature that will automatically extend the template to match the number of characteristics in your InspectionXpert project. 

See it in action in the video below: 

Download the PPAP Element 9 template we use in the video. If you'd like to try create your PPAP Dimensional Results Report with InspectionXpert, get started with free access. 

Other supporting documents for dimensional results

Depending on the requirements of your customer, instead of the above dimensional results report, you may be able to submit a checked print where the results are legibly written on a part drawing.

Want to learn more about PPAP? Read about all 18 elements and get our free PPAP Excel template. 

Published October 17, 2019. Updated August 3, 2020