Why Structured Material Data, Standardised Approval Workflows, and Automated Testing Interfaces Are Essential for Efficient PLM Integration in the Automotive Supply Chain – and How Brain of Materials Delivers the Operational Infrastructure
The Missing Link in PLM: Structured Raw Material Approval Data
Product Lifecycle Management (PLM) has become the central backbone of digital product
development across the automotive, aerospace, and manufacturing industries. PLM systems
manage engineering data, bills of materials (BOMs), change processes, and regulatory
compliance throughout the entire product lifecycle – from initial concept through design,
production, and end-of-life.
However, a critical area within PLM remains insufficiently digitalised in many organisations: the raw material approval process. While PLM systems excel at managing component-level data, the structured integration of material test data, sampling results, and quality-assured approval documentation into PLM workflows continues to be a significant challenge.
In practice, material approval processes – including PPAP (Production Part Approval Process), and First Article Inspection(FAI) as part of the broader APQP (Advanced Product Quality Planning) framework – are frequently managed outside the PLM system, relying on fragmented tools and manual data transfers. Analogue systems, Excel-based workflows, and document-driven coordination are holding back innovation across millions of product type approvals.
Typical consequences of this gap include:
- Disconnected material test data that cannot be automatically validated within PLM
workflows - Manual re-entry of approval results from PDF data sheets, Excel reports, or email-based laboratory communications
- Inconsistent interpretation of testing requirements across suppliers, laboratories, and
OEM specifications - Limited traceability between material approvals and the corresponding product structures in PLM
- Delayed PPAP and sampling timelines due to coordination overhead between quality,
engineering, and procurement - Inability to leverage historical material test data for cross-project benchmarking or
predictive quality analysis
complex multi-material portfolios, this disconnect translates directly into longer time-to-market, higher process costs, and increased compliance risk. The delays cost OEMs and suppliers millions due to lost productivity and missed market opportunities.
Why Raw Material Approval Is a Critical PLM Process
Raw material approval is not a peripheral activity – it is a foundational quality gate that
determines whether a product can proceed to series production. In the automotive industry,
every material used in a vehicle – from glass-fibre-reinforced polyamides to coated metals and elastomeric sealing compounds – must undergo rigorous testing and formal approval before it enters the production process.
The material approval process typically encompasses:
- Definition of testing requirements based on OEM specifications, international standards (ISO, DIN, ASTM), and internal quality guidelines
- Selection and commissioning of accredited testing laboratories
- Execution of mechanical, thermal, chemical, and environmental tests
- Documentation and evaluation of test results against defined acceptance criteria
- Generation of initial sample test reports and formal approval of the material for use in
specific applications and projects - Ongoing monitoring and re-qualification in case of material changes, supplier changes, or specification updates
Each of these steps generates data that is essential for PLM-integrated quality management,
regulatory compliance, and audit-proof documentation. When this data exists outside the PLM system – in isolated spreadsheets, PDF reports, or proprietary laboratory information
management systems (LIMS) – the digital thread is broken.
A truly integrated PLM environment requires structured, machine-readable material approval data that flows seamlessly between testing systems, quality management platforms (CAQ), enterprise resource planning (ERP) systems, and the PLM backbone.
VDA 231-301: The Standardised Interface for Material Test Data in PLM
Recognising the need for a harmonised, digital exchange format for material test data, the
German Association of the Automotive Industry (VDA) has published VDA 231-301. This
recommendation defines a standardised, machine-readable data model based on JSON
schemas for the structured description and exchange of testing requirements, testing
conditions, and result structures.
VDA 231-301 provides the semantic and technical foundation that enables material test data to be processed automatically within PLM systems and across organisational boundaries. For the raw material approval process, this means:
- Testing requirements can be communicated in a structured, unambiguous format from the OEM to the supplier and from the supplier to the testing laboratory
- Test results can be validated automatically against defined acceptance criteria upon
receipt within the PLM or CAQ system - The complete approval chain – from requirement definition through laboratory
commissioning to result evaluation – is documented in a consistent, audit-proof data format - Integration with existing PLM, CAQ, and ERP systems is enabled through standardised
JSON interfaces, eliminating manual data transfers and media discontinuities
VDA 231-301 builds upon and complements VDA 231-300, which standardises the embedding of material and surface requirements in 3D CAD data sets using the JT format (ISO 14306 / DIN SPEC 91383). Together, these recommendations create a continuous digital data chain from requirement specification in the product design through to the structured return of test results – closing the loop within PLM.
The TestID: Unique Identification of Testing Requirements for PLM Integration
One of the most persistent challenges in raw material approval is the ambiguous description of testing requirements. Standards and OEM specifications frequently contain formulations that leave room for interpretation – leading to iterative clarification cycles, inconsistent test results, and delays in the approval process.
The TestID (TID) addresses this challenge by assigning a unique, machine-readable identifier
to each testing requirement, including its methodology, parameterisation, and conditions. The TestID transforms vague, document-based testing specifications into precise digital specifications that can be processed automatically across systems and organisational boundaries. Within the VDA 231-301 framework, the TestID functions as a BusinessKey that bridges the gap between normative text and operational testing practice.
For PLM integration, the TestID provides critical value:
- Every material test within the approval process is referenced by a unique identifier that is consistent across all systems – PLM, CAQ, ERP, and laboratory systems
- Testing requirements encoded via TestID can be automatically compared with incoming test results, enabling rule-based validation within PLM workflows
- Cross-project and cross-supplier comparability is ensured, allowing organisations to build comprehensive material knowledge bases directly linked to their PLM data model
- Ambiguities that traditionally cause delays in PPAP and PPF processes are eliminated at
the point of requirement definition
The combination of standardised data structures (VDA 231-301) and unique test identification (TestID) transforms raw material approval from a document-based, coordination-intensive process into a data-driven, automatable workflow that integrates natively with PLM.
Want to See How This Works in Practice?
Book a complimentary webinar with our experts to explore how TestID-based digital
specifications and VDA 231-301 can be integrated into your specific PLM and quality
assurance landscape. We will walk through concrete integration scenarios tailored to your
supply chain.
Brain of Materials: The Operational Infrastructure for PLM-Integrated Material Approval
Brain of Materials is a digital platform for structured material data exchange that enables
organisations to close the gap between their PLM systems and the material approval process. The platform provides the operational infrastructure required to translate standardised data models into day-to-day practice – connecting OEMs, suppliers, material manufacturers, and testing laboratories on a single, TISAX-certified and ISO 9001-compliant environment.
Direct Utilisation of VDA 231-301 Data Models
Brain of Materials actively participates in the development of VDA 231-301 and enables direct utilisation of its data models within the platform. Organisations can configure test plans, exchange test results, and validate incoming data against defined specifications – all within a centralised environment that eliminates media discontinuities and is compatible with existing PLM, CAQ, and ERP system landscapes.
TestID-Based Test Plan Configuration
Using TestIDs, the configuration of a complete material test plan can be accomplished in under five minutes. Every testing requirement is unambiguously defined, ensuring that laboratories receive a complete, structured description of what is to be tested, under which conditions, and according to which specification. The need for iterative clarification between stakeholders is virtually eliminated – a prerequisite for scalable, PLM-integrated approval workflows.
Integrated Laboratory Commissioning
Brain of Materials provides direct access to a network of over 50 accredited testing laboratories through a single platform. Once a test plan has been configured, laboratories can be selected and commissioned directly – eliminating separate procurement workflows, fragmented email coordination, and ambiguous PDF attachments. Because testing requirements are communicated via TestIDs, laboratories no longer need follow-up questions about test scope – eliminating fragmented email coordination and ambiguous PDF attachments. Test results are automatically fed back into the platform, mapped to the corresponding TestIDs, and immediately available for evaluation, benchmarking, and downstream system integration.
AI-Assisted Legacy Data Conversion
A significant practical challenge in achieving full PLM integration of material approval data lies in the conversion of existing legacy data – historical test results stored in PDF data sheets, proprietary Excel templates, or isolated database exports. Brain of Materials addresses this challenge through a hybrid methodology that combines AI-based extraction, algorithmic mapping, and domain-expert validation. This enables organisations to transform legacy document repositories into a consistent, structured data source that can be integrated directly into their PLM systems.
Compatibility with PLM, CAQ, and ERP Systems
Brain of Materials is designed for compatibility with existing PLM, CAQ, and ERP system
landscapes. The platform provides standardised data interfaces based, for example, on VDA 231-301 and JSON schemas, enabling organisations to integrate structured material approval data into their downstream systems. When concrete integration requirements arise, the Brain of Materials software engineering team is available for timely implementation of tailored connectivity solutions.
Accelerating PPAP and Material Sampling Through PLM-Connected Data Flows
The Production Part Approval Process (PPAP)/ the PPF process (VDA Volume 2) are
among the most critical – and most coordination-intensive – milestones in the automotive
supply chain. Material test data constitutes a significant portion of the required PPAP
documentation, including material certifications, dimensional results, and performance test
summaries.
When material approval data is managed outside the PLM system, assembling a complete
PPAP package becomes a time-consuming, error-prone exercise. Engineers and quality
managers must manually collect test results from disparate sources, verify their completeness, and reformat them for submission – often under significant time pressure.
By connecting the material approval process to the PLM data model through standardised
interfaces (VDA 231-301) and unique test identification (TestID), organisations can achieve:
- Automated assembly of material-related PPAP documentation directly from structured test data
- Real-time visibility into the approval status of every material within the PLM system
- Significant reduction in PPAP cycle times through elimination of manual data collection
and reformatting - Consistent, audit-proof documentation that satisfies both OEM requirements and
regulatory standards such as IATF 16949 - Scalable approval workflows that can handle multi-material, multi-supplier programmes without proportional increases in coordination effort
Key Benefits of Integrating Raw Material Approval into PLM
Organisations that establish a structured, digital connection between their PLM systems and
the material approval process position themselves for measurable improvements across their entire quality assurance and product development lifecycle. Brain of Materials enables up to 45% efficiency gains through AI-enabled, standardised data processes in the initial phase and supports the reduction of pre-development and series-development time from 50 to 25 months until Start of Production (SOP).
- Reduced Process Costs: Elimination of manual data transfers, redundant data
collection, and iterative clarification cycles between quality, engineering, and procurement teams - Accelerated Time-to-Market: Automated validation of test results against acceptance
criteria shortens material approval and PPAP timelines significantly - Enhanced Data Quality and Consistency: Standardised, semantically clear data
structures reduce errors and improve comparability across projects, suppliers, and OEM programmes - Increased Scalability: A single, interoperable data interface replaces customer-specific
reporting formats, enabling efficient multi-OEM and multi-material operations - Audit-Proof Documentation: A continuous digital data chain from test commissioning
through to result evaluation satisfies regulatory, IATF 16949, and customer-specific quality management requirements - Future-Proof Infrastructure: Alignment with VDA 231-301, VDA 231-300, DIN SPEC
91383, and open-source JSON schemas ensures long-term interoperability and adaptability as standards evolve - Preservation of Institutional Knowledge: Material test data and associated metadata
are systematically captured in a durable, interoperable form – accessible across the
organisation and across the product lifecycle - Digital Delivery Specifications: Machine-readable delivery specifications and test
standards eliminate the need for manual interpretation and domain-specific knowledge at every handover point
A Practical Roadmap: Connecting Material Approval to Your PLM System
Organisations considering the integration of raw material approval data into their PLM
environment can follow a structured implementation approach:
- Assess the Current State: Inventory existing material test data formats, identify pain
points in current approval workflows, and evaluate the volume of legacy data requiring
conversion - Define PLM Integration Requirements: Determine which downstream systems – CAQ, ERP, MES – need to receive structured material approval data, and map the required data flows
- Adopt Standardised Data Models: Implement VDA 231-301 as the interface format for material test data exchange, leveraging JSON schemas for automated validation and system integration
- Implement the TestID Framework: Assign unique TestIDs to all testing requirements to ensure unambiguous identification and machine-readable referencing across the supply chain
- Convert Legacy Data: Transform historical material test data into the standardised data model using a hybrid methodology that combines automated extraction with expert validation
- Integrate and Validate: Connect the standardised material data interface to your PLM
system, establish automated validation rules, and verify end-to-end data flow - Scale Across the Supply Chain: Extend the standardised interface to suppliers,
laboratories, and OEM partners, establishing a fully digital, interoperable material approval chain
Summary
PLM systems provide the digital backbone for modern product development – but their value is fundamentally limited when critical quality data remains outside the integrated data model. Raw material approval, as one of the most data-intensive and coordination-dependent processes in the automotive supply chain, represents both a significant challenge and a significant opportunity for PLM optimisation.
The combination of standardised data exchange formats like the VDA 231-301, unique test
identification (TestID), and a dedicated operational platform for material data management
creates the foundation for a truly integrated, end-to-end digital process chain – from material requirement definition in the PLM system through laboratory commissioning, test execution, result validation, and formal approval.
Brain of Materials provides the infrastructure to make this integration operational: direct
utilisation of VDA 231-301 data models, TestID-based test plan configuration in under five
minutes, access to over 50 accredited laboratories, AI-assisted legacy data conversion, and
compatibility with existing PLM, CAQ, and ERP systems.
Organisations that close the gap between PLM and raw material approval will benefit from
reduced process costs, accelerated PPAP timelines, enhanced data quality, and a scalable,
audit-proof quality infrastructure that is ready for the demands of an increasingly digital and
interconnected supply chain.
Ready to Integrate Raw Material Approval into Your PLMWorkflow?
Would you like to understand how Brain of Materials can connect your material approval
process with your existing PLM system landscape – and what efficiency potentials can be
realised through structured, standardised data exchange?
In our complimentary webinar, we will demonstrate practical applications of how Brain of
Materials can serve as an operational infrastructure for testing and material data. Together, we will analyse typical PLM integration scenarios, automation potentials, and specific use cases along the supply chain.
Secure your appointment now and discuss your individual requirements directly with our experts.
