What is material approval? Definition and process

Material approval refers to the structured process for evaluating and approving materials before they are used in series production.

Core elements of material approval

The approval process includes several essential components that must be completed systematically:

• Technical specification review and material analysis
• Supplier qualification and First Article Inspection (FAI)
• Documentation of all test results and approval criteria
• Formal approval decision by authorized bodies

Material approval vs. production approval

While material approval focuses on individual materials and components, Production Approval covers the entire production process. Material approval is therefore an important prerequisite for subsequent series approval.

Importance of material approval in procurement

For procurement, material approval is a key instrument for minimizing risk. It enables the early identification of quality issues and creates legal certainty in supplier evaluation. Systematic Quality Inspection prevents costly rework and production downtime.

Key KPIs and target metrics for material approvals

Effective metrics enable the continuous monitoring and optimization of the material approval process as well as the evaluation of process quality.

Process efficiency metrics

Lead time from request to final approval is a key metric for process efficiency. Typical target values range between 2-4 weeks depending on material type and complexity. The first-pass yield rate measures the share of successful initial approvals without re-inspection and should be above 85%.

Quality metrics

The complaint rate of approved materials in series production indicates the effectiveness of the approval process. Target values below 100 PPM (Parts per Million) are considered a benchmark for high-quality approval processes. Cost of Poor Quality (COPQ) caused by rework and failures should be continuously reduced.

Supplier performance

The supplier approval rate evaluates the success rate of different suppliers in the approval process. Regular assessments of Delivery Quality and systematic supplier development improve overall performance. Documented Lessons Learned from approval processes promote continuous improvement.

Risks, dependencies, and countermeasures

Material approval involves various risks that can be successfully minimized through systematic risk analysis and preventive measures.

Quality and compliance risks

Incomplete or incorrect material inspections can lead to serious quality problems in production. Inadequate documentation makes traceability more difficult and can have legal consequences. Regular Supplier Audit Program and standardized inspection procedures significantly reduce these risks.

Time-related and operational dependencies

Delays in the approval process can jeopardize critical production deadlines and cause high follow-up costs. Dependencies on external testing laboratories or supplier capacities increase this risk. Parallel testing strategies and alternative suppliers create the necessary flexibility.

Strategic countermeasures

Robust risk management includes preventive and reactive components. FMEA identify potential weaknesses at an early stage. Established 8D Report ensure systematic root cause analysis and sustainable corrective actions when problems occur.