PPAP 20Workbook 20 20First 20Edition

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PPAP 20Workbook 20 20First 20Edition Powered By Docstoc
					  Production Part Approval Process (PPAP)




                                   First Edition
                                 October 4th, 2010


                       "One System…One Team...One Oshkosh”




OSK PPAP is based off of the Automotive Industry Action Group Production Part Approval Process

                                                                             PPAP: First Edition
                                                                                 Date: 10/4/10
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                                                   PPAP INTRODUCTION


PPAP packages are expected to be received by Oshkosh Corporation by the date assigned by Purchasing. If for any reason you cannot
meet this date, contact Purchasing for resolution.

It is the policy of Oshkosh Corporation to approve initial samples of supplier provided parts before receiving production orders of those parts
Oshkosh has developed the PPAP PROCESS to facilitate this requirement.
The Default PPAP is Level 2, unless otherwise required by the Oshkosh Segment Quality Representative
PPAP requirements apply to the following parts:
 1) New parts.
 2) Existing parts from a new supplier.
 3) Existing parts from existing supplier where there has been a substantive change in the
    supplier's manufacturing process, tooling, materials, and/or location.
 4) Any changes that affect the fit, function or appearance of the part.
 5) Any request by OSK based on part rejection history.

There may be occasions where parts may be excluded from the PPAP PROCESS requirements. These may include parts that are
manufactured to a higher standard or recognized external standard specification. Some examples of acceptable standards include ISO
(International Standard Organization), SAE (Society of Automotive Engineers), and NIST (National Institute of Standards and Technology)
among others. The supplier will have to provide documentation of higher standard or external standard specification. However, this will be
at the discretion of the responsible Oshkosh Corporation Quality Representative.

 Please reference the Oshkosh Corporation Global Supplier Quality Manual for more detail on PPAP
        requirements. The Manual can be retrieved on the https://www.oskgpsc.net/ website.

Important Note: These sheets have not been protected, so you can add additional information if needed. However, the information in blue
is interlinked to the other spreadsheets.
FILL IN THE BLUE SECTIONS FOR AUTOMATIC INPUT INTO FORMS


           Part Name                                                      NAME
           Part Number                                                    P-NUMBER
           Rev #                                                          REV #
           Engineering Change Level                                       ECN
           Engineering Change Level Date                                  ECN DATE
           Models / Vehicle                                               MODEL / VEHICLE


           Supplier Name                                                  SUPPLIER COMPANY
           Supplier Number                                                NUMBER
           Street Address                                                 ADDRESS
           City                                                           CITY
           State                                                          STATE
           Country                                                        COUNTRY
           Zip                                                            ZIP
           Phone Number                                                   555-555-5555
           Fax Number                                                     555-555-5554
           Application                                                    OSK MODEL

           Email Address                                                  Emailme@somewhere.com

              THE FOLLOWING LEVELS OF DOCUMENTS WERE USED TO PREPARE THIS WORKBOOK.
                    DOCUMENT                                       EDITION                                                          PRINTING
ADVANCED PRODUCT QUALITY PLANNING AND CONTROL PLAN               Second edition                                                      Jul-08
REFERENCE MANUAL
MEASUREMENT SYSTEM ANALYSIS                                                                      Third edition                        May-03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS                                                     Fourth edition                        Jun-08

PRODUCTION PART APPROVAL PROCESS                                                                Fourth edition                        Nov-09



                                                                                                                           PPAP: First Edition
                                                                                                                               Date: 10/4/10
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                                                                                Oshkosh Corporation
                                                                         PPAP Part Submission Requirements.

              Part Number:            P-NUMBER                        Purchase Order No.
            Revision Level:              ECN                            Part Description:                  NAME               ALL PPAP CRITERIA
            Supplier Name:        SUPPLIER COMPANY                   Reason for Request:                                      MUST CONFORM TO
                                                                                                                          Oshkosh Corporation Customer
          Supplier Number:             NUMBER                             OSK Program:                 OSK MODEL          Specifics defined in the Global
               Date Issued:                                         Submission Due Date:                                     Supplier Quality Manual

                                UNLESS OTHERWISED SPECIFIED IN WRITING BY OSHKOSH CORPORATION:
Default PPAP Submission Level 2 - Unless Otherwise Specified by Oshkosh Corportion
(Segment Specific Requirements may vary)
S = Supplier Must Send Items to Oshkosh Corporation for Approval
* = Supplier to Send items to Oshkosh Corporation Upon Request
                                                                                                                             Submission Level
                                  PPAP Submission Requirements and Detail Description                                        1      2      3
1.) Part Submission Warant (PSW)                                                                                             S      S      S
2.) Intitial Sample Inspection Report (ISIR)                                                                                 *      S      S
3.) Print Notes: (a. Material / b. Performance / c. Surface Finish / d. Labeling / e. Paint Test Results / f. Welding)       *      S      S
4.) Design Records - For all other components / details                                                                      *      *      S
5.) Engineering Change Documents (ECN) - if applicable                                                                       *      *      S
6.) Design Failure Modes effects Analysis (DFMEA) - if design responsible                                                    *      *      S
7.) Process Flow Diagram (PFD)                                                                                               *      *      S
8.) Process Failure Modes Effects Analysis (PFMEA)                                                                           *      *      S
9.) Initial Process Capability                                                                                               *      *      S
10.) Measurement System Analysis (MSA)                                                                                       *      *      S
11.) Qualified Laboratory Documentation                                                                                      *      *      S
12.) Process Control Plan                                                                                                    *      *      S
13.) Appearance Approval Report (AAR) - if applicable                                                                        *      *      S
14.) Master Sample - One Sample to be Identified as a Master Sample and Retained by Supplier (<$100)                         *      *      S
15.) Checking Aids (Fixture, gage, template, etc) - Specific to the part being submitted                                     *      *      S
16.) Records of Compliance with Customer Specific Requirements as specified                                                  *      *      S
17.) Sample Products For Layout                                                                                              *      *      S
                                                          Additional Submission Instructions below:




                                                                                                                         PPAP: First Edition
                                                                                                                             Date: 10/4/10
         3 of 48
                               PPAP SAMPLE PARTS - LABEL

Send identified sample(s), such as, Piece#1, Piece#2, Piece#3, etc to Oshkosh Corporation with appropriate label.

Please complete and attach this page on the outside of each package in plain view of a fork lift/material
handler/operator. Put the Packing slip pocket near the label.

In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts
laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is
protected from label adhesion.


                PPAP SAMPLE PARTS
              INSPECTION VERIFICATION REQUIRED

     Purchased Order#:

            Part Number:

       Revision Level:

       Supplier Name:

      Supplier Number:

  Supplier Inspected By:




                                                                                                PPAP: First Edition
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                                                                                      Part Submission Warrant
          Part Name                                   NAME                                  Oshkosh Part Number                             P-NUMBER
          Shown on Drawing Number                                                           Supplier Part Number

          Engineering Change Level                                                 ECN                                      Dated    ECN DATE
          Additional Engineering Changes                                                                                    Dated

          Safety and/or Government Regulation                     Yes         No            Purchase Order No.                                  Weight (kg)

          Checking Aid Number                                 Checking Aid Eng. Change Level                                                    Dated

          ORGANIZATION MANUFACTURING INFORMATION                                            CUSTOMER SUBMITTAL INFORMATION

          SUPPLIER COMPANY                                        NUMBER
          Organization Name & Supplier/Vendor Code                                          Customer Name/Division

          ADDRESS
          Street Address                                                                    Buyer/Buyer Code

          CITY                    STATE                 ZIP             U.S.A.              OSK MODEL
          City                     Region          Postal Code          Country             Application

          MATERIALS REPORTING

          Has customer-required Substances of Concern information been reported?                                     Yes            No            n/a

                           Submitted by IMDS or other customer format:


          Are polymeric parts identified with appropriate ISO marking codes?                                          Yes           No            n/a

          REASON FOR SUBMISSION (Check at least one)
                  Initial submission                                                                               Change to Optional Construction or Material
                  Engineering Change(s)                                                                            Sub-Supplier or Material Source Change
                  Tooling: Transfer, Replacement, Refurbishment, or additional                                     Change in Part Processing
                  Correction of Discrepancy                                                                        Parts produced at Additional Location
                  Tooling Inactive > than 1 year                                                                   Other - please specify


          REQUESTED SUBMISSION LEVEL (Check one)
                  Level 1 - Warrant only submitted to customer.
                  Level 2 - Warrant with product samples, ISIR, and Material/Performance/Surface Finish/Paint Test Results
                  (Check items that have been submitted within this PPAP submission)
                      1. Part Submission Warrant                    3a. Print Notes: Material Tests                   3d. Print Notes: Part Identification
                      2. Dimensional results (ISIR)                 3b. Print Notes: Surface Finish Tests             3e. Print Notes: Paint Tests
                      3. Print Notes                                3c. Print Notes: Functional Tests                 3f. Welding

                  Level 3 - All Level 2 Requirements in addition DFMEA, PFD, PFMEA, Control Plan, Initial Process Capability, and MSA
                  (Check items that have been submitted within this PPAP Submission - See PPAP Requirements Tab for Definition)
                              1    2    3     4     5    6    7    8     9    10    11 12     13 14 15 16 17



          DECLARATION
          I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all Production Part
          Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of __N/A__/__N/A__
          hours. I also certify that documented evidence of such compliance is on file and available for your review. I have noted any deviation from this
          declaration below.

          EXPLANATION/COMMENTS:


          Is each Customer Tool properly tagged and numbered?                         Yes          No               n/a

          Organization Authorized Signature                                                                                              Date

          Print Name                                              Phone No.                   555-555-5555                    Fax No.
          Title                                               E-mail

                                                          FOR CUSTOMER USE ONLY

          PPAP Warrant Disposition:           Approved             Rejected               Other
          Customer Signature                                                                                                             Date

          Print Name                                                               Customer Tracking Number (optional)


          DISTRIBUTION STATEMENT C: (Applies to all FMTV Technical Data)
          Distribution authorized to US government agencies and their contractors, Reason: Administrative or Operational Use. Date of Determination (Part
          Submission Warrant Supplier Completion Date). Other requests for this document shall be referred to: The Project Manager, Medium Tactical
          Vehicles, Attn: Engineering Director, Mail Stop #500, 6501 East 11 Mile Road, Warren, MI 48397-5000 DSN 786-6622 or Commercial (586) 282-
          6622



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                                                   DIMENSIONAL RESULTS (ISIR)

ORGANIZATION:                                    SUPPLIER COMPANY                           PART NUMBER:   P-NUMBER
SUPPLIER NUMBER:                                     NUMBER                                 PART NAME:     NAME

NAME OF INSPECTION FACILITY:                                                                DESIGN RECORD CHANGE LEVEL:                  ECN
DATE:                                                                                       ENGINEERING CHANGE DOCUMENTS:

Supplier required to provide marked up print to identify items inspected.

                                             SPECIFICATION /                                 ORGANIZATION MEASUREMENT RESULTS (DATA)
                                                                            GAGE    QTY.                                                       NOT
ITEM DIMENSION / SPECIFICATION                   LIMITS                                                                                   OK
                                                                            TYPE   TESTED       Piece 1       Piece 2         Piece 3          OK
                                             MIN        MAX




                                          Blanket statements of conformance are unacceptable for any test results.

        PRINT NAME                       SIGNATURE                                 TITLE                                  DATE




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                                                                    PRINT NOTES
                        (MATERIAL, SURFACE FINISH, PERFORMANCE TESTS & PART IDENTIFICATION)


ORGANIZATION:                                   SUPPLIER COMPANY                               PART NUMBER:   P-NUMBER
SUPPLIER NUMBER:                                    NUMBER                                     PART NAME:     NAME

NAME OF INSPECTION FACILITY:                                                                   DESIGN RECORD CHANGE LEVEL:                  ECN
DATE:                                                                                          ENGINEERING CHANGE DOCUMENTS:

Supplier required to provide marked up print to identify all PRINT NOTES inspected.

                                            SPECIFICATION /                                     ORGANIZATION MEASUREMENT RESULTS (DATA)
                                                                         GAGE          QTY.                                                       NOT
ITEM          SPECIFICATION                     LIMITS                                                                                       OK
                                                                         TYPE         TESTED       Piece 1       Piece 2         Piece 3          OK
                                            MIN        MAX




                                        Blanket statements of conformance are unacceptable for any test results.

        PRINT NAME                      SIGNATURE                                     TITLE                                  DATE




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                                                                   PRINT NOTES
                                                                    (PAINT TESTING)

ORGANIZATION:                                      SUPPLIER COMPANY                            PART NUMBER:   P-NUMBER
SUPPLIER NUMBER:                                       NUMBER                                  PART NAME:     NAME

NAME OF INSPECTION FACILITY:                                                                   DESIGN RECORD CHANGE LEVEL:                 ECN
DATE:                                                                                          ENGINEERING CHANGE DOCUMENTS:

Supplier required to provide marked up print to identify all PRINT NOTES inspected.

                                                 SPECIFICATION /                                     SUPPLIER TEST RESULTS (DATA)
                                                                             GAGE      QTY.                                                     NOT
ITEM               SPECIFICATION                     LIMITS                                                                                OK
                                                                             TYPE     TESTED      Piece 1       Piece 2         Piece 3         OK
                                                 MIN        MAX
Prime Coat:
        Permeability
        Thickness
        Adhesion
        Salt Spray
        Ambient Cure Time (if used)
        Oven Cure Time (if used)
Top Coat:

        Permeability
        Thickness
        Adhesion
        Salt Spray
        Ambient Cure Time (if used)
        Oven Cure Time (if used)
Document Painting Method / Industry Standard used to prepare these components.

        (ie method 1)




                                             Blanket statements of conformance are unacceptable for any test results.

        PRINT NAME                           SIGNATURE                                TITLE                                 DATE




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                                                                           PRINT NOTES
                                                                             (WELDING)

ORGANIZATION:                                        SUPPLIER COMPANY                                      PART NUMBER:   P-NUMBER
SUPPLIER NUMBER:                                         NUMBER                                            PART NAME:     NAME

NAME OF INSPECTION FACILITY:                                                                               DESIGN RECORD CHANGE LEVEL:                ECN
DATE:                                                                                                      ENGINEERING CHANGE DOCUMENTS:

Supplier required to provide marked up print to identify ALL Weld items.


                                                                                        PQR#                        CHECK FOR CONFORMANCE                     NOT
ITEM               SPECIFICATION / WELD SYMBOL                             WPS#                                                                          OK
                                                                                  (IF NOT PRE-QUALIFIED)                                                      OK
                                                                                                             WELD SIZE    WELD LENGTH      WELD QTY




                                         Blanket statements of conformance are unacceptable for any test results.

        PRINT NAME                       SIGNATURE                                TITLE                                                  DATE




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          9 of 48
                                          APPEARANCE APPROVAL REPORT

PART                                                               DRAWING                                               APPLICATION
NUMBER       P-NUMBER                                              NUMBER                                                (VEHICLES)          MODEL / VEHICLE
PART                                                               BUYER                             E/C LEVEL                        DATE
NAME         NAME                                                  CODE                                     ECN
ORGANIZATION                                            MANUFACTURING                                                                 SUPPLIER / VENDOR
NAME         SUPPLIER COMPANY                           LOCATION                                                                      CODE         NUMBER
REASON FOR           PART SUBMISSION WARRANT            SPECIAL SAMPLE                               RE-SUBMISSION                    OTHER
SUBMISSION           PRE TEXTURE                        FIRST PRODUCTION SHIPMENT                    ENGINEERING CHANGE
                                                        APPEARANCE EVALUATION
                                                                                                                                       AUTHORIZED CUSTOMER
                         ORGANIZATION SOURCING AND TEXTURE INFORMATION                                             PRE-TEXTURE         REPRESENTATIVE
                                                                                                                   EVALUATION          SIGNATURE AND DATE
                                                                                                                  CORRECT AND
                                                                                                                    PROCEED
                                                                                                                  CORRECT AND
                                                                                                                    PROCEED
                                                                                                                   APPROVED TO
                                                                                                                  ETCH/TOOL/EDM

                                                           COLOR EVALUATION
                                                                                                                                      METALLIC     COLOR
COLOR      TRISTIMULUS DATA   MASTER MASTER MATERIAL MATERIAL                HUE               VALUE        CHROMA        GLOSS       BRILLIANCE SHIPPING      PART
SUFFIX DL* Da* Db* DE* CMC NUMBER     DATE       TYPE    SOURCE    RED     YEL   GRN   BLU   LIGHT   DARK   GRAY CLEAN   HIGH   LOW   HIGH   LOW   SUFFIX   DISPOSITION




COMMENTS



ORGANIZATION                         PHONE NO.          DATE                     AUTHORIZED CUSTOMER                                               DATE
SIGNATURE                                                                        REPRESENTATIVE SIGNATURE


                                                                                                                                                     PPAP: First Edition
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                                                    DFMEA - DESIGN FAILURE MODES EFFECTS ANALYSIS

             System

             Subsystem                                                      Design Responsibility:                                       FMEA Number:
             Component                                                                  Key Date:                                             Prepared by:
     Model Year(s)/Vehicle(s):               MODEL / VEHICLE                                                                                  Date (Orig.):
Core Team:                                                                                                                                    Date (Rev.):
                                                                        C         Potential          O   Current       D                       Responsibility
                                 Potential             Potential                                                                                                          Action Results
                                                                    S   l                            c   Design        e   R.
   Item /                                                                        Causes(s)/                                     Recommended      & Target
               Requirements       Failure              Effect(s)    e   a                            c   Controls      t   P.                                                    S    O    D   R.
  Function                                                                      Mechanism(s)                                      Action(s)     Completion      Actions
                                  Mode                 of Failure   v   s                            u   -Prevention   e   N.                                                    e    c    e   P.
                                                                                 of Failure          r   -Detection    c                           Date         Taken            v    c    t   N.
                                                                        s




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                        PROCESS/INSPECTION FLOWCHART


   Product Program               MODEL / VEHICLE           Issue Date                    ECL       ECN
   Supplier Name                SUPPLIER COMPANY           Part Name                    NAME
   Supplier Location                ADDRESS                Part Number               P-NUMBER


   Legend:
      Operation           Transportation           Inspection            Delay                  Storage

           Operation or Event                Description of                           Evaluation
                                           Operation or Event                    and Analysis Methods


      Operation

      Inspection

     Transportation

           Storage

     Transportation

      Operation

      Operation

      Inspection

      Operation

      Operation

      Operation

      Inspection

      Inspection

      Operation

      Inspection

      Inspection

      Operation


                   Change History
       Date                                              Revision


                                                                                            PPAP: First Edition
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12 of 48
                                                      PFMEA - PROCESS FAILURE MODES & EFFECTS ANALYSIS



Print #               P-NUMBER                     Rev.   REV #                                                                              FMEA Number:
Item:                     n/a                                                  Process Responsibility:                                            Prepared by:
          Model Year(s)/Vehicle(s): MODEL / VEHICLE                                         Key Date:                                             Date (Orig.)
  Core Team:                                                                                                                                      Date (Rev.)
                                                                           C                             O    Current      D
                                                                                       Potential                                                   Responsibility             Action Results
 Process Step /                        Potential          Potential    S   l                             c   Process       e   R.
                                                                           a          Causes(s)/         c   Controls      t   P.   Recommended      & Target                        S    O    D   R.
    Function          Requirements      Failure           Effect(s)    e             Mechanism(s)                                     Action(s)     Completion      Actions
                                        Mode              of Failure   v   s                             u   -Prevention   e   N.                                                    e    c    e   P.
                                                                                       of Failure                                                      Date         Taken
                                                                           s                             r   -Detection    c                                                         v     c   t   N.




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                                                                          CONTROL PLAN

    Prototype           Pre-Launch            Production
Control Plan Number                                 Key Contact/Phone                                              Date (Orig.)        Date (Rev.)
                                                                                                                       1/1/1996                      1/1/1996
Part Number/Latest Change Level                     Core Team                                                      Customer Engineering Approval/Date (If Req'd.)
P-NUMBER
Part Name/Description                               Supplier/Plant Approval/Date                                   Customer Quality Approval/Date (If Req'd.)
NAME
Supplier/Plant                Supplier Code         Other Approval/Date (If Req'd.)                                Other Approval/Date (If Req'd.)
                                     NUMBER
 PART/                MACHINE,                      CHARACTERISTICS             SPECIA                         METHODS
       PROCESS NAME/
PROCES                 DEVICE                                                     L                                                                        REACTION
         OPERATION                                                                     PRODUCT/PROCESS EVALUATION/      SAMPLE
   S                 JIG, TOOLS                                                 CHAR.                                                     CONTROL            PLAN
        DESCRIPTION                           NO.    PRODUCT      PROCESS                SPECIFICATION/ MEASUREMENT
NUMBER                FOR MFG.                                                  CLASS                                SIZE   FREQ.         METHOD
                                                                                          TOLERANCE      TECHNIQUE




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                     TOOLING & FIXTURES - PROPERTY OF OSHKOSH CORP.

ORGANIZATION:                                 SUPPLIER COMPANY                                PART NUMBER:     P-NUMBER
SUPPLIER NUMBER:                                  NUMBER                                      PART NAME:       NAME

TOOL / FIXTURE NUMBER:                                                                        DESIGN RECORD CHANGE LEVEL:                  ECN
DATE:                                                                                         ENGINEERING CHANGE DOCUMENTS:

Supplier is required to identify all Oshkosh Owned Tools & Fixtures and document with Photo in PPAP workbook

                                                    PHOTO OF OSHKOSH OWNED TOOLING AND FIXTURES




        PRINT NAME                     SIGNATURE                                    TITLE                                   DATE




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                                                                                                                         30 Pc. Capability Study/Ongoing Process Control
                                                                                                                                 (Individual Moving Range Chart)


Plant:                                                                                                                               Dept:                                                            Operation:                                                                                             Part Name:                                                                                                                   Part Number:
Station:                                                                                                                             Characteristic:                                                                                                                 Sample Size:                                                                                                                 Frequency taken:
                                               Upper Specification Limit:                                                                                                                   Lower Specification Limit:                                                                                                      Tol: 6 Sigma Lower:



                                     1.0000
                                     0.9000
     IMR Bar Chart




                                     0.8000
                                     0.7000
                                     0.6000
                                     0.5000
                                     0.4000
                                     0.3000
                                     0.2000
                                     0.1000
                                     0.0000
                                                   1           2           3            4           5           6            7           8           9        10        11         12        13        14           15        16        17        18        19        20           21     22        23        24        25        26        27        28          29        30        31           32        33        34        35        36        37        38       39       40       41          42       43        44




                                    1.0000
                                    0.8000
     Range Chart




                                    0.6000
                                    0.4000
                                    0.2000
                                    0.0000
                                               1           2           3            4           5           6            7           8           9           10        11         12        13        14          15         16        17        18        19        20        21        22        23        24        25        26        27        28          29        30        31           32        33        34        35        36        37        38       39       40       41          42       43        44




                                               Do not delete any numbers from the "Reading" cells after they are typed in. Rather Highlight the cells, right click your mouse and click on "Clear Contents".

   Date/Time
    Reading
      Range                                                        0           0            0           0           0            0           0           0         0         0          0         0         0            0         0         0         0         0        0         0         0         0         0         0         0         0         0           0         0         0             0        0         0         0         0         0         0        0        0        0           0        0         0
DATA POINT #                                           1           2           3            4           5           6            7           8           9        10        11         12        13        14          15         16        17        18        19        20        21        22        23        24        25        26        27        28          29        30        31           32        33        34        35        36        37    38       39       40       41           42      43        44

                      30 Pc.
                     Capability   Ongoing                              0.45
    INFO               Study      Statistics                           0.40
Avg Xbar
UCLx                                                                   0.35
LCLx
Std. Dev.                                                              0.30
Cr
                                                                       0.25
Avg Range
UCLr                                                                   0.20
Z Upper
Z Lower                                                                0.15
Skewness
Kurtosis                                                               0.10
Cpk Upper
                                                                       0.05
Cpk Lower
Average                                                                0.00
MAX                                                                            0.0000                           0.1000                           0.2000                          0.3000                         0.4000                       0.5000                       0.6000                   0.7000                        0.8000                        0.9000                          1.0000
MIN
Cp




                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                  PPAP: First Edition
                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                      Date 10/4/10
                                                         Criteria
            Effect                            Severity of Effect on Product                                 Rank
                                                   (Customer Effect)

                              Potential failure mode affects safe vehicle operation and/or involves
                                 noncompliance with government regulation without warning.
                                                                                                              10
   Failure to Meet Safety
     and/or Regulatory
       Requirements           Potential failure mode affects safe vehicle operation and/or involves
                                   noncompliance with government regulation with warning.
                                                                                                               9


                            Loss of primary function (vehicle inoperable, does not affect safe vehicle
                                                            operation)
                                                                                                               8
   Loss or Degradation of
     Primary Function
                            Degradation of primary function (vehicle operable, but at reduced level of
                                                          performance)
                                                                                                               7


                             Loss of secondary function (vehicle operable, but comfort/convenience
                                                     functions inoperable)
                                                                                                               6
   Loss or Degradation of
    Secondary Function
                                   Degradation of secondary function (vehicle operable, but
                                comfort/convenience functions at reduced level of performance)
                                                                                                               5



                             Appearance or Audible Noise, vehicle operable, item does not conform
                                          and noticed by most customers (> 75%).
                                                                                                               4


                             Appearance or Audible Noise, vehicle operable, item does not conform
           Annoyance
                                           and noticed by many customers (50%).
                                                                                                               3


                             Appearance or Audible Noise, vehicle operable, item does not conform
                                      and noticed by discriminating customers (< 25%).
                                                                                                               2



           No effect                                 No discernible effects.                                   1




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                                                                           Criteria: Occurrence of
 Likelihood of     Criteria: Occurrence of Cause - DFMEA                       Cause - DFMEA
                                                                                                             Rank
    Failure         (Design life/reliability of item/vehicle)                   (Incidents per
                                                                                 item/vehicle)
                                                                               ≥ 100 per thousand
   Very High          New technology/new design with no history.
                                                                                    ≥ 1 in 10
                                                                                                               10


                 Failure is inevitable with new design, new application,         50 per thousand
                      or change in duty cycle/operating conditions                   1 in 20
                                                                                                                9


                  Failure is likely with new design, new application, or         20 per thousand
       High                                                                                                     8
                       change in duty cycle/operating conditions                     1 in 50



                 Failure is uncertain with new design, new application,          10 per thousand
                      or change in duty cycle/operating conditions                   1 in 100
                                                                                                                7


                 Frequent failures associated with similar designs or in         2 per thousand
                             design simulation and testing.                         1 in 500
                                                                                                                6


                 Occasional failures associated with similar designs or          .5 per thousand
    Moderate              in design simulation and testing.                         1 in 2,000
                                                                                                                5



                 Isolated failures associated with similar designs or in         .1 per thousand
                              design simulation and testing.                        1 in 2,000
                                                                                                                4


                 Only isolated failures associated with almost identical        .01 per thousand
                       design or in design simulation and testing.                1 in 100,000
                                                                                                                3

       Low
                 No observed failures associated with almost identical         ≤ .001 per thousand
                      design or in design simulation and testing.                 1 in 1,000,000
                                                                                                                2



                                                                           Failure is eliminated through
    Very Low        Failure is eliminated through preventive control
                                                                                preventive control.
                                                                                                                1




                                                                                                   PPAP: First Edition
                                                                                                       Date: 10/4/10
18 of 48
 Opportunity                             Criteria:
                                                                                           Rank   Likelihood of Detection
for Detection           Likelihood of Detection by Design Control

  No detection
                     No current design control; Cannot detect or is not analyzed.           10      Almost Impossible
  opportunity

  Not likely to       Design analysis/detection controls have a weak detection
 detect at any         capability; Virtual Analysis (e.g. CAE, FEA, etc.) is not            9          Very Remote
    stage               correlated to expected actual operating conditions.

                     Product verification/validation after design freeze and prior to
                   launch with pass/fail testing (Subsystem or system testing with
                    acceptance criteria such as ride handling, shipping evaluation,
                                                                                            8             Remote
                                                   etc.)

  Post Design      Product verification/validation after design freeze and prior to
Freeze and prior launch with test to failure testing (Subsystem or system testing           7           Very Low
   to launch          until failure occurs, testing of system interactions, etc.)

                    Product verification/validation after design freeze and prior to
                   launch with degradation testing (Subsystem or system testing             6               Low
                              after durability test, e.g. function check).

                   Product validation (reliability testing, development or validation
                      tests) prior to design freeze using pass/fail testing (e.g.           5           Moderate
                     acceptance criteria for performance, function checks, etc.)


Prior to Design    Product validation (reliability testing, development or validation
    Freeze        tests) prior to design freeze using test to failure (e.g. until leaks,    4        Moderately High
                                           yields, cracks, etc.)

                   Product validation (reliability testing, development or validation
                  tests) prior to design freeze using degradation testing (e.g. data        3               High
                                    trends, before/after values, etc.)
                     Design analysis/detection controls have a strong detection
Virtual Analysis -   capability. Virtual Analysis (e.g. CAE, FEA, etc.) is highly
                   correlated with actual or expected operating conditions prior to
                                                                                            2           Very High
    Correlated
                                            design freeze.
 Detection not
                    Failure cause or failure mode can not occur because it is fully
  applicable;
                      prevented through design solutions (e.g., proven design               1         Almost Certain
    Failure
                          standard, best practice or common material, etc.)
  Prevention




                                                                                                       PPAP: First Edition
                                                                                                           Date: 10/4/10
   19 of 48
                                                Criteria                                                                                        Criteria:
     Effect                          Severity of Effect on Product                              Rank          Effect                 Severity of Effect on Process
                                          (Customer Effect)                                                                        (Manufacturing/Assembly Effect)

                     Potential failure mode affects safe vehicle operation and/or involves                                       May endanger operator (machine or assembly)
                        noncompliance with government regulation without warning.                10                                            without warning
 Failure to Meet
                                                                                                       Failure to meet safety
  Safety and/or
                                                                                                         and/or regulatory
   Regulatory
                     Potential failure mode affects safe vehicle operation and/or involves                  requirement       May endanger operator (machine or assembly) with
 Requirements                                                                                    9
                          noncompliance with government regulation with warning.                                                                 warning



                   Loss of primary function (vehicle inoperable, does not affect safe vehicle                                   100% of product may have to be scrapped. Line
                                                   operation)                                    8       Major Disruption
                                                                                                                                           shutdown or stop ship.
    Loss or
 Degradation of
Primary Function                                                                                                                A portion of the production run may have to be
                   Degradation of primary function (vehicle operable, but at reduced level of
                                                 performance)                                    7     Significant disruption scrapped. Deviation from primary process including
                                                                                                                                  decreased line speed or added manpower.


                    Loss of secondary function (vehicle operable, but comfort/convenience                                      100% of product may have to be reworked off line
                                            functions inoperable)                                6                                             and accepted.
     Loss or
 Degradation of
                                                                                                       Moderate disruption
   Secondary
    Function              Degradation of secondary function (vehicle operable, but                                               A portion of the production run may have to be
                       comfort/convenience functions at reduced level of performance)            5                                       reworked off line and accepted.



                    Appearance or Audible Noise, vehicle operable, item does not conform                                      100% of production run may have to be reworked in
                                  and noticed by most customers (> 75%).                         4                                      station before it is processed.
                                                                                                       Moderate disruption
                    Appearance or Audible Noise, vehicle operable, item does not conform                                         A portion of the production run may have to be
  Annoyance                       and noticed by many customers (50%).                           3                                 reworked in-station before it is processed.


                    Appearance or Audible Noise, vehicle operable, item does not conform                                         Slight inconvenience to process, operation, or
                             and noticed by discriminating customers (< 25%).                    2       Minor disruption
                                                                                                                                                   operator.



   No effect                                No discernible effects.                              1           No effect                       No discernible effect.




                                                                                                                                                        PPAP: First Edition
                                                                                                                                                            Date: 10/4/10
        20 of 48
           Likelihood   Criteria: Occurrence of Cause - PFMEA
                                                                            Rank
           of Failure        (Incidents per items/vehicles)


                                      ≥ 100 per thousand
           Very High                       ≥ 1 in 10                         10


                                        50 per thousand
                                            1 in 20                          9



             High                       20 per thousand
                                            1 in 50                          8


                                        10 per thousand
                                            1 in 100                         7


                                        2 per thousand
                                           1 in 500                          6




           Moderate                     .5 per thousand
                                           1 in 2,000                        5



                                        .1 per thousand
                                           1 in 10,000                       4


                                       .01 per thousand
                                         1 in 100,000                        3

             Low
                                      ≤ .001 per thousand
                                         1 in 1,000,000                      2



           Very Low     Failure is eliminated through preventive control.    1




                                                                                   PPAP: First Edition
                                                                                       Date: 10/4/10
21 of 48
           Opportunity for                           Criteria:                                         Likelihood of
                                                                                                Rank
             Detection              Likelihood of Detection by Process Control                           Detection


              No detection           No current process control; Cannot detect or is not                   Almost
                                                                                                 10
              opportunity                                analyzed.                                       Impossible


           Not likely to detect    Failure Mode and/or Error (Cause) is not easily detected
                                                                                                 9      Very Remote
             at any stage                           (e.g. random audits)



           Problem Detection         Failure Mode detection post-processing by operator
                                                                                                 8        Remote
            Post Processing                  through visual/tactile/audible means.

                                     Failure Mode detection in-station by operator through
           Problem Detection        visual/tactile/audible means or post-processing through
                                                                                                 7        Very Low
               at Source               use of attribute gauging (go/no go, manual torque
                                                    check/clicker wrench, etc.)
                                      Failure Mode detection post-processing by operator
           Problem Detection       through use of variable gauging or in-station by operator
                                                                                                 6          Low
            Post Processing       through use of attribute gauging (go/no go, manual torque
                                                    check/clicker wrench, etc.)
                                Failure Mode or Error (Cause) detection in-station by
                             operator through use of variable gauging or by automated
           Problem Detection
                             controls in-station that will detect discrepant part and notify     5        Moderate
               at Source
                             operator (light, buzzer, etc.). Gauging performed on setup
                                    and first-piece check (for set-up causes only).

                                   Failure Mode detection post-processing by automated
           Problem Detection
                                   controls that will detect discrepant part and lock part to    4     Moderately High
            Post Processing
                                                  prevent further processing.

                                    Failure Mode detection in-station by automated controls
           Problem Detection
                                   that will detect discrepant part and prevent automatically    3          High
               at Source
                                        lock part in station to prevent further processing.

            Error Detection        Error (Cause) detection in-station by automated controls
            and/or Problem          that will detect error and prevent discrepant part from      2        Very High
              Prevention                                   being made.

                                    Error (Cause) prevention as a result of fixture design,
             Detection not
                                  machine design or part design. Discrepant parts cannot be
           applicable; Failure                                                                   1     Almost Certain
                                       made because item has been error-proofed by
              Prevention
                                                  process/product design.




                                                                                                                         PPAP: First Edition
                                                                                                                             Date: 10/4/10
22 of 48
                             GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
                                          ATTRIBUTE METHOD


Part Number                             Gage Name                                    Appraiser
P-NUMBER
Part Name                               Gage Number                                  Date Performed
NAME
Characteristic                          Gage Type                  Upper Limit                        Lower Limit




        ATTRIBUTE DATA
 #       XT     a      P'a                            After entering data, follow the directions on the tab marked
 1                   0.000                            'Graph' to create the Gage Performance Curve
 2                   0.000
 3                   0.000
 4                   0.000
 5                   0.000
 6                   0.000
 7                   0.000
 8                   0.000
 9                   0.000


     FROM THE GRAPH
     ENTER THE FOLLOWING:
       XT (P=.5) =
        XT (P=.995) =
        XT (P=.005) =




                                            Measurement Unit Analysis
 Bias                                                  Repeatability
                 B   =                                        R          =
                     =                                                   =

 t Statistic
                 t   =   31.3 IBI / R                                    t0.025,19         =              2.093
                     =
                     =

 Result




                                                      Reviewed
                                                                                                 Title

                                                                                                                    PPAP: First Edition
                                                                                                                        Date: 10/4/10
         23 of 48
Directions for Gage Performance Curve for Attribute Analytical Method Form

1) Click Tools - Data Analysis - Regression
   (If Data Analysis is not available load Analysis Tool Pak from the Add-Ins menu)
2) In the box for Input Y Range select the cells GR&R ATT(L)!D14:D22
3) In the box for Input X Range select the cells GR&R ATT(L)!B14:B22
4) In the box for Output range select the cells below A23:M60
5) Check Line Fit Plots
6) Press OK
7) Copy the Line Fit plot graph to the space on the Analytic sheet
8) Change the graph title to Gage Performance Curve
9) Change the x axis to Xt
10) Change the y axis to Probability




                                                                                      PPAP: First Edition
                                                                                          Date: 10/4/10
        24 of 48
GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE RISK METHOD

Part Number                        Gage Name                   Date Performed              Appraiser A
P-NUMBER
Part Name                          Gage Number                 Gage Type                   Appraiser B
NAME
Characteristic                     Upper Specification         Lower Specification         Appraiser C



                                                         DATA TABLE
                                                                                                         Reference
 PART            A-1   A-2   A-3     B-1      B-2        B-3     C-1       C-2       C-3    Reference      Value       Code
   1
   2
   3
   4
   5
   6
   7
   8
   9
  10
  11
  12
  13
  14
  15
  16
  17
  18
  19
  20
  21
  22
  23
  24
  25
  26
  27
  28
  29
  30
  31
  32
  33
  34
  35
  36
  37
  38
  39
  40

                                                                                                           PPAP: First Edition
                                                                                                               Date: 10/4/10
  25 of 48
GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE RISK METHOD

Part Number                             Gage Name                   Date Performed                Appraiser A
P-NUMBER
Part Name                               Gage Number                 Gage Type                     Appraiser B
NAME
Characteristic                          Upper Specification         Lower Specification           Appraiser C




                                                   DATA TABLE CONTINUED
                                                                                                                Reference
 PART            A-1     A-2      A-3     B-1      B-2        B-3       C-1       C-2       C-3    Reference      Value       Code
  41
  42
  43
  44
  45
  46
  47
  48
  49
  50




            Risk Analysis
                                             A * B Crosstabulation

                                                                              B
                                                                                                      Total
                                                                    0                   1
                             0   Count                              0                   0               0
                                 Expected Count
                 A
                             1   Count                              0                   0               0
                                 Expected Count
                                 Count                              0                   0               0
                     Total
                                 Expected Count


                                             B * C Crosstabulation

                                                                              C
                                                                                                      Total
                                                                    0                   1
                             0   Count                              0                   0               0
                                 Expected Count
                 B
                             1   Count                              0                   0               0
                                 Expected Count
                                 Count                              0                   0               0
                     Total
                                 Expected Count
                                                                                                                  PPAP: First Edition
                                                                                                                      Date: 10/4/10
  26 of 48
GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE RISK METHOD

Part Number                            Gage Name             Date Performed        Appraiser A
P-NUMBER
Part Name                              Gage Number           Gage Type             Appraiser B
NAME
Characteristic                         Upper Specification   Lower Specification   Appraiser C




                                            A * C Crosstabulation

                                                                     C
                                                                                       Total
                                                             0                1
                             0   Count                       0                0          0
                                 Expected Count
                 A
                             1   Count                       0                0          0
                                 Expected Count
                                 Count                       0                0          0
                     Total
                                 Expected Count


                 Kappa                A                 B            C
                   A                  -
                   B                                     -
                   C                                                 -


               DETERMINATION
            AxB
            AxC
            BxC



                                                             Approved for Use                       Date




                                                                                                 PPAP: First Edition
                                                                                                     Date: 10/4/10
  27 of 48
                   GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET                                                                                              GAGE R
                                VARIABLE DATA RESULTS
       Part Number                                        Gage Name                                 Appraiser A
           P-NUMBER
       Part Name                                          Gage Number                               Appraiser B
           NAME
       Characteristic                    Specification    Gage Type                                 Appraiser C
                                       Lower Upper
       Characteristic Classification                      Trials               Parts                Appraisers             Date Performed




           APPRAISER/                                                        PART                                                      AVERAGE
           TRIAL #             1          2         3         4          5          6         7         8          9         10
           1. A         1
           2.           2
           3.           3
           4.       AVE                                                                                                              xa=
           5.           R                                                                                                            ra=
           6. B         1
           7.           2
           8.           3
           9.       AVE                                                                                                              xb=
           10.          R                                                                                                            rb=
           11. C        1
           12.          2
           13.          3
           14.      AVE                                                                                                              xc=
           15.          R                                                                                                            rc =
           16. PART                                                                                                                 X=
             AVERAGE                                                                                                                Rp=

           17.     (ra + rb + rc) / (# OF APPRAISERS) =                                                                              R=
           18.     xDIFF = (Max x - Min x) =                                                                                       xDIFF=
           19.     * UCLR =     R x D4 =                                                                                           UCLR=


       * D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
       beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
       discard values and re-average and recompute       R and the limiting value from the remaining observations.

       Notes:




                                                                                                                                            PPAP: First Edition
                                                                                                                                                Date: 10/4/10
28 of 48
              GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                           VARIABLE DATA RESULTS
  Part Number                         Gage Name                                     Appraiser A
  P-NUMBER
  Part Name                           Gage Number                                   Appraiser B
  NAME
  Characteristic                      Gage Type                                     Appraiser C


  Characteristic Classification       Trials                     Parts              Appraisers          Date Performed




                       Measurement Unit Analysis                                              % Total Variation (TV)
   Repeatability - Equipment Variation (EV)
     EV            =       R x K1                                 Trials    K1         % EV        =    100 (EV/TV)
                   =                                                 2     0.8865                  =
                   =                                                 3     0.5907                  =
   Reproducibility - Appraiser Variation (AV)
    AV       =      {(xDIFF x K2)2 - (EV2/nr)}1/2                                      % AV        =    100 (AV/TV)

                   =                                                                               =
                   =                                                                               =
                                                    Appraisers       2       3
           n = parts         r = trials                K2         0.7087   0.5236
   Repeatability & Reproducibility (GRR)                                             % GRR         =    100 (GRR/TV)
                                  2       2   1/2
    GRR            =       {(EV + AV )}                            Parts    K3                     =
                   =                                                 2     0.7087                  =
                   =                                                 3     0.5236
   Part Variation (PV)                                               4     0.4464
    PV         =    RP x K3                                          5     0.4032      % PV        =    100 (PV/TV)
                   =                                                 6     0.3745                  =
                   =                                                 7     0.3534                  =
   Total Variation (TV)                                              8     0.3378
      TV           =       {(GRR2 + PV2)}1/2                         9     0.3247       ndc        =    1.41(PV/GRR)
                   =                                                10     0.3145                  =
                   =                                                                               =



    For information on the theory and constants used in the form see MSA Reference Manual , Third edition.




                                                                                                                         PPAP: First Edition
                                                                                                                             Date: 10/4/10
29 of 48
             GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET                                                                                     GA
                          VARIABLE DATA RESULTS
 Part Number                                        Gage Name                                Appraiser A
 P-NUMBER
 Part Name                                          Gage Number                              Appraiser B
 NAME
 Characteristic                   Specification     Gage Type                                Appraiser C
                                 Lower Upper
 Characteristic Classification                      Trials               Parts               Appraisers              Date Performed



 APPRAISER/                                                           PART                                                       AVERAGE
 TRIAL #                 1         2          3         4         5          6         7         8         9           10
 1. A             1
 2.               2
 3.               3
 4.           AVE                                                                                                             xa=
 5.               R                                                                                                           ra=
 6. B             1
 7.               2
 8.               3
 9.           AVE                                                                                                             xb=
 10.              R                                                                                                           rb=
 11. C            1
 12.              2
 13.              3
 14.          AVE                                                                                                              xc=
 15.              R                                                                                                            rc=
 16. PART                                                                                                                     X=
   AVERAGE                                                                                                                    Rp =

 17.         (ra + rb + rc) / (# OF APPRAISERS) =                                                                              R=
 18.         xDIFF = (Max x - Min x) =                                                                                       xDIFF=
 19.         * UCLR =     R x D4 =                                                                                           UCLR=


 * D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
 beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
 discard values and re-average and recompute      R and the limiting value from the remaining observations.

 Notes:




                                                                                                                             PPAP: First Edition
                                                                                                                                 Date: 10/4/10
30 of 48
            GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                         VARIABLE DATA RESULTS
Part Number                            Gage Name                                   Appraiser A
P-NUMBER
Part Name                              Gage Number                                 Appraiser B
NAME
Characteristic                         Gage Type                                   Appraiser C


Characteristic Classification          Trials                   Parts              Appraisers            Date Performed



                     Measurement Unit Analysis                                                   % Tolerance (Tol)
 Repeatability - Equipment Variation (EV)
   EV            =       R x K1                                  Trials    K1         % EV          =    100 (EV/Tol)
                 =                                                  2     0.8865                    =
                 =                                                  3     0.5907                    =
 Reproducibility - Appraiser Variation (AV)
  AV       =      {(xDIFF x K2)2 - (EV2/nr)}1/2                                       % AV          =    100 (AV/Tol)

                 =                                                                                  =
                 =                                                                                  =
                                                   Appraisers       2       3
         n = parts        r = trials                  K2         0.7087   0.5236
 Repeatability & Reproducibility (GRR)                                              % GRR           =    100 (GRR/Tol)
                                2       2   1/2
  GRR            =       {(EV + AV )}                             Parts    K3                       =
                 =                                                  2     0.7087                    =
                 =                                                  3     0.5236
 Part Variation (PV)                                                4     0.4464
  PV         =    RP x K3                                           5     0.4032      % PV          =    100 (PV/Tol)
                 =                                                  6     0.3745                    =
                 =                                                  7     0.3534                    =
 Tolerance (Tol)                                                    8     0.3378
   Tol           =       Upper - Lower / 6                          9     0.3247       ndc          =    1.41(PV/GRR)
                 =       ( Upper - Lower ) / 6                     10     0.3145                    =
                 =                                                                                  =



  For information on the theory and constants used in the form see MSA Reference Manual , Third edition.




                                                                                                                    PPAP: First Edition
                                                                                                                        Date: 10/4/10
      31 of 48
              GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                               ANOVA METHOD
Part Number                                       Gage Name                       Appraiser A
P-NUMBER
Part Name                                         Gage Number                     Appraiser B
NAME
Characteristic                   Specification    Gage Type                       Appraiser C
                                Lower Upper
Characteristic Classification                     Trials            Parts         Appraisers        Date Performed



APPRAISER/                                                        PART                                               AVERAGE
TRIAL #                1         2         3          4       5          6   7        8         9       10
1. A             1
2.               2
3.               3
4.          AVE                                                                                              xa=
5.               R                                                                                           ra=
6. B             1
7.               2
8.               3
9.          AVE                                                                                              xb=
10.              R                                                                                           rb=
11. C            1
12.              2
13.              3
14.         AVE                                                                                               xc=
15.              R                                                                                            rc=
16. PART                                                                                                      X=
     AVERAGE                                                                                                 Rp =




            Anova Table
            Source                               DF                SS            MS                 F        Sig
            Appraiser
            Parts
            Appraiser-by-Part
            Equipment
            Total
                                                                                  * Significant at a = 0.05 level


                                                                                                              PPAP: First Edition
                                                                                                                  Date: 10/4/10
 32 of 48
              GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                               ANOVA METHOD
Part Number                                      Gage Name                     Appraiser A
P-NUMBER
Part Name                                        Gage Number                   Appraiser B
NAME
Characteristic                   Specification   Gage Type                     Appraiser C
                                Lower Upper
Characteristic Classification                    Trials          Parts         Appraisers        Date Performed




                                                  Standard
                                                                   % Total Variation         % Contribution
            Anova Report                         Deviation (s)
            Repeatability (EV)
            Reproducibility (AV)
            Appraiser by Part (INT)
            GRR
            Part-to-Part (PV)


            Note:
            Tolerance =                                                        Total variation (TV) =
            Number of distinct data categories (ndc) =




                                                                                                           PPAP: First Edition
                                                                                                               Date: 10/4/10
 33 of 48
                                                             GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                      Gage Name                      Appraiser A
   P-NUMBER
   Part Name                                        Gage Number                    Appraiser B
   NAME
   Characteristic                   Specification   Gage Type                      Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials            Parts        Appraisers        Date Performed



   APPRAISER/                                                       PART                                         AVERAGE
   TRIAL #                 1        2         3         4       5          6   7      8          9     10
   1. A             1
   2.               2
   3.               3
   4.          AVE                                                                                             xa=
   5.               R                                                                                          ra=
   6. B             1
   7.               2
   8.               3
   9.          AVE                                                                                             xb=
   10.              R                                                                                          rb=
   11. C            1
   12.              2
   13.              3
   14.         AVE                                                                                             xc=
   15.              R                                                                                          rc =
   16. PART                                                                                                   X=
      AVE ( Xp )                                                                                              Rp=




                                                                                                                PPAP: First Edition
                                                                                                                    Date: 10/4/10
34 of 48
                                                               GAGE R&R

                     GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                                   GRAPHICAL ANALYSIS
   Part Number                                        Gage Name                    Appraiser A
   P-NUMBER
   Part Name                                          Gage Number                  Appraiser B
   NAME
   Characteristic                     Specification   Gage Type                    Appraiser C
                                     Lower Upper
   Characteristic Classification                      Trials        Parts          Appraisers       Date Performed



   Note:             The REFERENCE VALUE can be substituted for PART AVE to generate graphs indication true bias.

                                                      Average Chart -"Stacked"

                      1.00
                      0.90
                      0.80                                                                               Appraiser A
                      0.70
           Average




                      0.60                                                                               Appraiser B
                      0.50                                                                               Appraiser C
                      0.40
                                                                                                         Upper Spec
                      0.30
                      0.20                                                                               Lower Spec
                      0.10
                      0.00
                                 1     2       3      4   5   6    7        8      9    10
                                                       Part Number

                     Analysis:




                                                      Range Chart -"Stacked"

                     1.00
                     0.90
                     0.80
                     0.70                                                                                Appraiser A
                     0.60                                                                                Appraiser B
           Range




                     0.50
                     0.40                                                                                Appraiser C
                     0.30                                                                                Rucl
                     0.20
                     0.10
                     0.00
                                 1    2       3       4      5    6   7     8     9     10
                                                          Part Number

                     Analysis:
                                                                                                                PPAP: First Edition
                                                                                                                    Date: 10/4/10
35 of 48
                                                             GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                      Gage Name             Appraiser A
   P-NUMBER
   Part Name                                        Gage Number           Appraiser B
   NAME
   Characteristic                   Specification   Gage Type             Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials        Parts   Appraisers    Date Performed




                                                                                                   PPAP: First Edition
                                                                                                       Date: 10/4/10
36 of 48
                                                                 GAGE R&R

                       GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                                     GRAPHICAL ANALYSIS
   Part Number                                          Gage Name               Appraiser A
   P-NUMBER
   Part Name                                            Gage Number             Appraiser B
   NAME
   Characteristic                      Specification    Gage Type               Appraiser C
                                      Lower Upper
   Characteristic Classification                        Trials        Parts     Appraisers    Date Performed




                                                       Average Chart -"Unstacked"

                        1.00
                        0.90
                        0.80
                        0.70
             Average




                        0.60
                        0.50
                        0.40
                        0.30
                        0.20
                        0.10
                        0.00
                                   1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
                                       Appr A                          Appr B                      Appr C

                       Analysis:




                                                       Range Chart -"Unstacked"

                        1.00
                        0.90
                        0.80
                        0.70
           Average




                        0.60
                        0.50
                        0.40
                        0.30
                        0.20
                        0.10
                        0.00
                                   1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
                                       Appr A                          Appr B                     Appr C

                       Analysis:


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                                                                                                             Date: 10/4/10
37 of 48
                                                             GAGE R&R

                   GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                                 GRAPHICAL ANALYSIS
   Part Number                                      Gage Name                          Appraiser A
   P-NUMBER
   Part Name                                        Gage Number                        Appraiser B
   NAME
   Characteristic                   Specification   Gage Type                          Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials          Parts              Appraisers        Date Performed




                                                                Run Chart

                    1.00
                    0.90
                    0.80
                    0.70
                    0.60
           Value




                    0.50
                    0.40
                    0.30
                    0.20
                    0.10
                    0.00
                               1          2         3           4     5            6       7         8         9          10
                                                                            Part

                   Analysis:




                                                                                                                    PPAP: First Edition
                                                                                                                        Date: 10/4/10
38 of 48
                                                                  GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                          Gage Name                   Appraiser A
   P-NUMBER
   Part Name                                            Gage Number                 Appraiser B
   NAME
   Characteristic                       Specification   Gage Type                   Appraiser C
                                       Lower Upper
   Characteristic Classification                        Trials         Parts        Appraisers    Date Performed




                                                                                                                                   Supp
                                                                 Scatter Plot
                                                                                                                                      A
           1.00                                                                                                                       B
           0.90                                                                                                                       C
           0.80
           0.70
           0.60
                                                                                                                                      A
           0.50                                                                                                                       B
           0.40                                                                                                                       C
           0.30
           0.20
           0.10
           0.00
                              Part 1




                                                                           Part 3




                                                                                                            Part 5
                                                                 Scatter Plot

           1.00
           0.90
           0.80
           0.70
           0.60
           0.50
           0.40
           0.30
           0.20
           0.10
           0.00
                                                                                                            Part 10
                              Part 6




                                                                           Part 8




               Analysis:




                                                                                                             PPAP: First Edition
                                                                                                                 Date: 10/4/10
39 of 48
                                                             GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                      Gage Name                      Appraiser A
   P-NUMBER
   Part Name                                        Gage Number                    Appraiser B
   NAME
   Characteristic                   Specification   Gage Type                      Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials            Parts        Appraisers        Date Performed




                                                    Whiskers Chart - Appraiser A                                                       Supp

       1.00                                                                                                                            Appr
       0.90
       0.80
       0.70
       0.60
       0.50
       0.40                                                                                                                            Appr
       0.30
       0.20
       0.10
       0.00
               1              2          3           4            5           6      7           8           9          10             Appr


                                                    Whiskers Chart - Appraiser B

       1.00
       0.90
       0.80
       0.70
       0.60
       0.50
       0.40
       0.30
       0.20
       0.10
       0.00
              1               2          3           4            5           6      7           8           9          10



                                                    Whiskers Chart - Appraiser C

       1.00
       0.90
       0.80
       0.70
       0.60
       0.50
       0.40
       0.30
       0.20
       0.10
       0.00
              1               2         3            4            5           6      7           8           9          10



                  Analysis:


                                                                                                                 PPAP: First Edition
                                                                                                                     Date: 10/4/10
40 of 48
                                                                 GAGE R&R

                 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                               GRAPHICAL ANALYSIS
   Part Number                                          Gage Name                 Appraiser A
   P-NUMBER
   Part Name                                            Gage Number               Appraiser B
   NAME
   Characteristic                       Specification   Gage Type                 Appraiser C
                                       Lower Upper
   Characteristic Classification                        Trials        Parts       Appraisers    Date Performed




                                                                 Error Chart

             1                                                                                                                   A
           0.9                                                                                                                   B
           0.8                                                                                                                   C
           0.7
           0.6
           0.5                                                                                                                   A
           0.4                                                                                                                   B
           0.3                                                                                                                   C
           0.2
           0.1
             0
                              Part 1




                                                                         Part 3




                                                                                                           Part 5
                                                                 Error Chart

             1
           0.9
           0.8
           0.7
           0.6
           0.5
           0.4
           0.3
           0.2
           0.1
             0
                             Part 6




                                                                         Part 8




                                                                                                          Part 10




                 Analysis:



                                                                                                           PPAP: First Edition
                                                                                                               Date: 10/4/10
41 of 48
                                                              GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                       Gage Name                Appraiser A
   P-NUMBER
   Part Name                                         Gage Number              Appraiser B
   NAME
   Characteristic                   Specification    Gage Type                Appraiser C
                                   Lower Upper
   Characteristic Classification                     Trials        Parts      Appraisers    Date Performed




                                                    Normalized Histogram - Error

           1
       0.8
       0.6
                                                                                                             Appr A
       0.4
       0.2
           0




                                               Normalized Histogram - Error

         1
       0.9
       0.8
       0.7
       0.6
       0.5                                                                                                   Appr B
       0.4
       0.3
       0.2
       0.1
         0




                                                    Normalized Histogram - Error

           1
       0.8
       0.6
                                                                                                             Appr C
       0.4
       0.2
           0




               Analysis:


                                                                                                       PPAP: First Edition
                                                                                                           Date: 10/4/10
42 of 48
                                                             GAGE R&R

               GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                             GRAPHICAL ANALYSIS
   Part Number                                      Gage Name                      Appraiser A
   P-NUMBER
   Part Name                                        Gage Number                    Appraiser B
   NAME
   Characteristic                   Specification   Gage Type                      Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials          Parts          Appraisers    Date Performed




                                     XY Plot of Averages by Size

        1.00
        0.90
        0.80
        0.70
        0.60                                                                                                  Appr A
        0.50                                                                                                  Appr B
                                                                                                              Appr C
        0.40
        0.30
        0.20
        0.10
        0.00
            0.00               2.00            4.00          6.00           8.00     10.00       12.00


               Analysis:




                                                                                                            PPAP: First Edition
                                                                                                                Date: 10/4/10
43 of 48
                                                               GAGE R&R

                    GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                                  GRAPHICAL ANALYSIS
   Part Number                                      Gage Name                 Appraiser A
   P-NUMBER
   Part Name                                        Gage Number               Appraiser B
   NAME
   Characteristic                   Specification   Gage Type                 Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials          Parts     Appraisers    Date Performed




                                                    Comparison XY Plot

                    1.00
                    0.90
                    0.80
                    0.70
                    0.60
           Appr B




                    0.50
                    0.40
                    0.30
                    0.20
                    0.10
                    0.00
                        0.00            2.00                 4.00     6.00      8.00        10.00            12.00
                                                                     Appr A



                                                    Comparison XY Plot

                    1.00
                    0.90
                    0.80
                    0.70
                    0.60
           Appr C




                    0.50
                    0.40
                    0.30
                    0.20
                    0.10
                    0.00
                        0.00            2.00                 4.00     6.00      8.00        10.00            12.00
                                                                     Appr A


                                                                                                       PPAP: First Edition
                                                                                                           Date: 10/4/10
44 of 48
                                                             GAGE R&R

                    GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
                                  GRAPHICAL ANALYSIS
   Part Number                                      Gage Name              Appraiser A
   P-NUMBER
   Part Name                                        Gage Number            Appraiser B
   NAME
   Characteristic                   Specification   Gage Type              Appraiser C
                                   Lower Upper
   Characteristic Classification                    Trials        Parts    Appraisers    Date Performed




                                                    Comparison XY Plot

                    1.00
                    0.90
                    0.80
                    0.70
                    0.60
           Appr C




                    0.50
                    0.40
                    0.30
                    0.20
                    0.10
                    0.00
                        0.00           2.00              4.00      6.00     8.00         10.00            12.00
                                                                  Appr B


                    Analysis:




                                                                                                    PPAP: First Edition
                                                                                                        Date: 10/4/10
45 of 48
                                                                                                            X BAR & R
                                                                                                    VARIABLES CONTROL CHART

                                                           VARIABLES CONTROL CHART ( x & R )                                                       PART NO.                                                 CHART NO.
                                                           MEASUREMENT EVALUATION                                                                  P-NUMBER
           PART NAME (Product)                                                                             OPERATION (Process)                                           SPECIFICATION LIMITS
           NAME
           APPRAISER A                        APPRAISER B                              APPRAISER C                    MACHINE                GAGE                  UNIT OF MEASURE              ZERO EQUALS


                  x=                                   UCL =                                    LCL =                                        AVERAGES (X BAR CHART)

                 1.00

                 0.90

                 0.80

                 0.70

                 0.60

                 0.50

                 0.40

                 0.30

                 0.20

                 0.10

                 0.00
                         1     2      3         4      5       6       7       8         9      10   11     12   13    14   15     16   17    18    19   20   21    22    23   24    25    26    27    28    29     30


                  r=                                   UCL =                                    LCL =                                              RANGES (R CHART)


                  1.00

                  0.90

                  0.80

                  0.70

                  0.60

                  0.50

                  0.40

                  0.30

                  0.20

                  0.10

                  0.00
                         1        2       3        4       5       6       7       8        9   10    11    12   13    14   15     16   17    18    19   20   21    22    23   24   25    26    27    28    29    30



                                                           APPRAISER A                                                          APPRAISER B                                             APPRAISER C
                PART
                              1       2        3       4       5       6       7        8       9    10     1    2     3    4     5     6     7     8    9    10    1     2    3    4     5      6    7      8     9     10
               NUMBER


           R       1
           E       2
           A
           D       3
           I
           N       4
           G
           S       5

                SUM

                 SUM
           x
                 NUM
                 HIGH-
           R
                 LOW


                             ** = POINT OUT OF CONTROL




                                                                                                                                                                                                                  PPAP: First Edition
                                                                                                                                                                                                                      Date: 10/4/10
46 of 48
                                                                           X BAR & R
                                                                   VARIABLES CONTROL CHART

                                          VARIABLES CONTROL CHART ( x & R )                              PART NO.                                   CHART NO.
                                          MEASUREMENT EVALUATION                                         P-NUMBER
           PART NAME (Product)                                           OPERATION (Process)                            SPECIFICATION LIMITS
           NAME
           APPRAISER A           APPRAISER B             APPRAISER C              MACHINE            GAGE           UNIT OF MEASURE       ZERO EQUALS




                      Computations for the Control Chart Method of Evaluating a Measurement Process
             REPLICATION ERROR:                 Average Subgroup Range = r =                                                          r      d2
                                                                                                                                      2    1.126
                                                Number of replications = Subgroup Size = r =                                          3    1.693
                                                                                                                                      4    2.059
                                                Estimate Replication Standard Deviation r / d2 = se =                                 5    2.326

             CALCULATION FOR APPRAISER EFFECT:                                                                                  Appraiser Averages

                         no        d2*          Number of Appraisers = nA =                                  0                Appraiser        Average
                         2        1.410                                                                                          A
                         3        1.906         Number of Samples = n =                                      0                   B
                                                                                                                                 C
                                                Range of Appraiser Averages = RA =                          0.00

                                                Appraiser Effect = RA / d2* = sA =

             CALCULATIONS FOR MEASUREMENT ERROR STANDARD DEVIATION:

                                               sm     = SQRT ( se + sA )

             CALCULATIONS FOR SIGNAL TO NOISE RATIO:                                                                             Sample Averages

                         no        d2*          Range for these Sample Averages = Rp =                      0.00               Sample          Average
                         2        1.410                                                                                           1
                         3        1.906         Estimate Sample to Sample Standard Deviation:                                     2
                         4        2.237                                                                                           3
                         5        2.477                                           sp   =    Rp / d2* =                            4
                         6        2.669                                                                                           5
                         7        2.827         Signal to Noise Ratio:                                                            6
                         8        2.961                                                sp / sm =                                  7
                         9        3.076                                                                                           8
                         10       3.178                                                                                           9
                                                                                                                                 10


                     Thus the number of distinct categories that can be reliably distinguished by these measurements is:

                                     ndc =      1.41 x sp / sm =




                     This is the number of non-overlapping 97% confidence intervals that will span the range of product variation. (A 97% confidence
                     interval centered on a single measurement would contain the actual product value that is represented by that measurement 97%
                     of the time.)




                                                                                                                                                         PPAP: First Edition
                                                                                                                                                             Date: 10/4/10
47 of 48
                                                          GAGE STUDY - X BAR & R

                                         GAGE R STUDY                                            PART NO.                            CHART NO.
                               MEASUREMENT EVALUATION                                            P-NUMBER
PART NAME (Product)                                                 OPERATION (Process)                      ZERO EQUALS
NAME
APPRAISER                      MACHINE               GAGE                     UNIT OF MEASURE        UPPER SPECIFICATION   LOWER SPECIFICATION


    AVERAGES (X BAR CHART)
     x=              UCL =                                           LCL =


     1.00
     0.90
     0.80
     0.70
     0.60
     0.50
     0.40
     0.30
     0.20
     0.10
     0.00
             1                 2             3              4                 5              6         7          8              9         10



    RANGES (R CHART)
     r=                             UCL =                            LCL =



      1.00
      0.90
      0.80
      0.70
      0.60
      0.50
      0.40
      0.30
      0.20
      0.10
      0.00
                 1              2            3                  4             5           6            7          8          9           10




READING               1    2    3   4    5       6    7     8        9   10

    VALUE

     HIGH-
R                    n/a   0    0   0    0       0    0     0        0    0
     LOW


                     ** = POINT OUT OF CONTROL


                                                                GAGE R ANALYSIS
    Data in control?                                                     % Repeatability =

    This method CANNOT be used for final gage acceptance without other complete and detailed MSA methods.



                                                                                                                             PPAP: First Edition
                                                                                                                                 Date: 10/4/10
 48 of 48

				
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