PPAP Submission Checklist RevC

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					PPAP Submission Checklist
                  TRW Part Number:                                        Description:                                                   Revision Level:                                                          PPAP Submission Level:
                                                                                                                                                                                                                                                                           ADDITIONAL REVIEWS
                  Customer:                                Program:                                           Using Location:                                                                                   Component Priority Level:
                                                                                                                                                                                                                                                                          DATE

                                            SUPPLIER INFORMATION                                                                               TRW INFORMATION                                                     STATUS DESCRIPTION

           Company Name:                                                                                      Product Line:                                                                  R (Red): Major issue or missing. Corrective Action Required.

           Company Location:                                                                                  Product:                                                                       Y (Yellow): Minor issue(s). Corrective Action Required.

           Supplier Code:                                                                                     Reviewer:                                                                      G (Green): Meets requirements.

           Contact Name:                                              Phone:                                  Resp. SDE:                                                                     NA (Not Applicable): Requirement does not apply.

           Contact Email:                                                                                     Review Date:

NOTE: Regardless of the PPAP Submission Level, all the elements of a PPAP package must be completed.




                                                                                                                                                 Supplier Results
Only those documents that are either marked "S" or requested by the SDE/SQA must be submitted to TRW.                PPAP Submission                                                                                                  CORRECTIVE ACTION




                                                                                                                                                                    TRW Results
The entire package is to be retained by the Supplier.                                                                     Level


   No.                                                   DOCUMENT                                                        1   2   3   4   5
                                                                                                                                                                                  COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
    1      Part Submission Warrant                                                                                       S   S   S   S   R
            A.    PART NUMBER AND REVISION LEVEL MUST MATCH THE DRAWING
            B.    WEIGHT INCLUDED (TAKEN FROM A MINIMUM OF 10 RANDOMLY SELECTED PIECES WITH FOUR DECIMAL PLACES IN KILOGRAMS)
            C.    SUBMISSION INFORMATION COMPLETE:
                  1. SUPPLIER MANUFACTURING INFORMATION COMPLETE, INCLUDING SUPPLIER CODE
                  2. ALL APPROPRIATE BOXES CHECKED
                  3. BUYER NAME/BUYER CODE (OPTIONAL) INCLUDED
                  4. APPLICATION INFORMATION INCLUDES TRW CUSTOMER AND PROGRAM
            D.    ELV/IMDS INFORMATION INCLUDED (IF YOU ARE NOT USING PTS)
                  1. THE IMDS NUMBER IS FOLLOWED BY A " / " AND THEN AN INTEGER NUMBER
            E.    CORRECT REASON FOR SUBMISSION BOX CHECKED (IF "OTHER" IS CHECKED, THE CORRECT REASON FOR SUBMISSION IS NOTED)
            F.    CORRECT SUBMISSION LEVEL BOX IS CHECKED (IF YOU ARE NOT USING PTS)
            G.    THE SUBMISSION RESULTS AREA IS PROPERLY FILLED OUT AND THE PACKAGE REFLECTS THIS
                  1. THE SUBMISSION RESULTS AREA OF THE PSW MUST REFLECT THE STATE OF CONFORMANCE FOR DIMENSIONAL MEASUREMENTS,
                     MATERIAL AND FUNCTIONAL TESTS, APPEARANCE CRITERIA, AND STATISTICAL PROCESS PACKAGE DOCUMENTS.
                  2. FOR MULTIPLE TOOLS/CAVITIES/PROCESSES THE INFORMATION IS NOTED IF APPLICABLE
            H.    THE DECLARATION AREA CONTAINS THE PRODUCTION RATE INFORMATION
             I.   SIGNATURE AREA IS COMPLETED AND CONTAINS ALL INFORMATION
             J. PURCHASE ORDER INFORMATION IS INCLUDED
    2      Design Records (Drawings, Specifications)                                                                  R      S   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   A MARKED OR BALLOONED DRAWING IS ATTACHED WITH ALL THE DRAWING DIMENSIONS AND NOTES NUMBERED
             B.   COPIES OF ALL REFERENCED SPECIFICATIONS & CROSS REFERENCED SPECIFICATIONS ARE INCLUDED IN THE SUBMISSION

    3      Change Documents                                                                                           R      S   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   PART NUMBER AND REVISION LEVEL MUST MATCH THE DRAWING
             B.   PART APPLICATION / PROGRAM / PLANTS IDENTIFIED
            C.    SPECIFIES TIME SPAN OR VOLUME AFFECTED
            D.    ACTION PLAN INCLUDED IF REQUEST IS FOR DEVIATION/CONCESSION
             E.   SIGNED AND DATED BY TRW

    4      Customer Engineering Approval Documents                                                                    R      R   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
                  A. IF PROCESS INCORPORATES UNRELEASED CHANGE, COPY OF ENGINEERING DOCUMENT INCLUDED

    5      Design FMEA                                                                                                R      R   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE

             A.   PART NUMBER AND REVISION LEVEL SHOULD MATCH THE DRAWING
             B.   DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT
            C.    THE SEVERITIES, OCCURRENCES AND DETECTIONS MATCH THE LATEST AIAG REQUIREMENTS

    6      Process Flow Diagram                                                                                       R      R   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   PART NUMBER AND REVISION LEVEL SHOULD MATCH THE DRAWING
             B.   SHOULD INCLUDE WHOLE PRODN PROCESS REFLECTING CRITICAL/SIGNIFICANT CHARACTERISTICS AND
                  MANUFACTURING STEPS

    7      Process FMEA                                                                                               R      R   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   PART NUMBER AND REVISION LEVEL SHOULD MATCH THE DRAWING
             B.   DOES IT FOLLOW THE ENTIRE PROCESS AS SHOWN IN FLOW CHART
            C.    DO HIGH RPN FAILURE MODES HAVE ACTIONS SHOWN FOR IMPROVEMENT
            D.    SEVERITIES OF THE DFMEA ARE CARRIED OVER INTO THE PFMEA
             E.   THE SEVERITIES MATCH THE TRW REQUIREMENTS
             F.   THE SEVERITIES, OCCURRENCES AND DETECTIONS MATCH THE LATEST AIAG REQUIREMENTS
            G.    CRITICAL FEATURES IDENTIFIED ON THE PCM, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL PROCESS
                  CONTROLS, ETC.) ARE INCLUDED IN THE PFMEA AND HAVE RPN VALUES CALCULATED. HAVE THE LAUNCH CONCERNS,
                  PROCESS CHANGES AND TOOL TUNING LOOPS BEEN INCLUDED IN THE PFMEA

    8      Dimensional Results                                                                                        R      S   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   ALL DIMENSIONS AND NOTES ON THE DRAWING ARE INCLUDED &TRACEABLE TO BALLOON NUMBER
             B.   THERE IS A SEPARATE REPORT FOR EACH CAVITY, DIE, TOOL, LINE, ETC… THE ORGANIZATION SHALL COMPLETE A
                  DIMENSIONAL EVALUATION IN ONE PART OF EACH
            C.    EACH FORM IS FILLED OUT COMPLETELY, PREFERABLY USING AN ELECTRONIC FORMAT WITH FORMULAS THAT INDICATE IF
                  THE DIMENSION/CHARACTERISTIC MEETS OR NOT THE PRINT
            D.    WHEN SAMPLES ARE SUBMITTED, THE SAMPLE NUMBER CORRESPONDS WITH THE DATA
             E.   ALL THE DIMENSIONS ARE MARKED AS "OK" UNLESS THERE IS AN APPROVED DEVIATION OR CONCESSION. IF NON-CONFORMANCES
                  ARE DOCUMENTED, BOTH THE SUBMISSION RESULTS AND DECLARATION AREAS ON THE WARRANT SHOULD INDICATE NON-COMPLIANCE
             F.   DIMENSIONS ARE REPORTED IN THE SAME UNITS AS ON THE TRW OR CUSTOMER DRAWING
            G.    LAYOUTS OF SUBCOMPONENTS AND/OR ASSEMBLIES ARE DOCUMENTED AND AVAILABLE
            H.    IS MAXIMUM REGRIND CONFIRMED
             I.   ARE ALL THE HARD TO QUANTIFY FEATURES LISTED? (FLASH, NICKS, DENTS, BURRS, POROSITY, ETC)

    9      Material & Performance Test Results                                                                        R      S   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   ACTUAL TEST LABORATORY DATA IS INCLUDED IN THE PACKAGE
             B.   CERTIFIED LABORATORY USE (INCLUDED ARE COPIES OF CERTIFICATION AND SCOPE OF ACCREDITATION)
            C.    DATA SHOWS TEST REQUIREMENTS AND RESULTS FOR EACH TEST, DETAILED IN EACH SPECIFICATION/STANDARD REFERENCED ON
                  THE DRAWING
            D.    TRW PART NUMBER AND REVISION LEVEL ARE INCLUDED ON EACH PAGE FOR ALL DATA
             E.   IS THE DATA LESS THEN ONE YEAR OLD

   10      Initial Process Study                                                                                      R      R   S   *   R                                        COMMENTS                     ACTION                           RESPONSIBILITY       TARGET DATE
             A.   STUDIES ARE CONDUCTED FOR ALL CRITICAL AND SIGNIFICANT CHARACTERISTICS (EXCEPT DIMENSIONS WITH BONUS TOLERANCES)
             B.   TEN (10) MEASUREMENTS FOR BONUS TOLERANCE DIMENSIONS ARE INCLUDED
            C.    Cpk's/Ppk's MEET THE REQUIREMENTS FOR DESIGNATED CHARACTERISTICS
            D.    IF NO, A WRITTEN CORRECTIVE ACTION STATEMENT, FOR EACH, IS INCLUDED AND CONTAINMENT, WHEN FEASIBLE, IS
                  100% INSPECTION
             E.   RAW DATA AND NORMALITY TEST ARE INCLUDED FOR EACH STUDY
             F.   PROCESS AVERAGES MATCH FOR MULTIPLE CAVITIES, DIES AND TOOL PROCESSES
            G.    FOR VARIABLE DATA, A MINIMUM OF 25 SUBGROUPS CONTAINING AT LEAST 100 READINGS FROM CONSECUTIVE PARTS OF THE
                  SIGNIFICANT PRODUCTION RUN
            H.    FOR ATTRIBUTE DATA , A MINIMUM OF 300 READINGS FROM CONSECUTIVE PARTS OF THE SIGNIFICANT PRODUCTION RUN
             I.   CAPABILITY REPORTS MUST HAVE THE HISTOGRAM, CONTROL CHARTS AND NORMALITY STUDY




         Date: 28 May 2010
         Revision: D
         Doc No: D_020_4_19                                                                                                                                                                                                                                 Process Owner/Department:
         Page 1 of 29                                                                                                    PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls                                                                   L. VanDongen / Supplier Development
11     Measurement Systems Analysis (Gage R&R)                                                                 R    R   S    *    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   STUDIES ARE INCLUDED FOR ALL NEW AND MODIFIED GAGES USED TO MEASURE THE CHARACTERISTICS LISTED IN THE PCM
         B.   THE GAGE R& R COMPUTATION IS PRESENTED ON THE FORM LISTED IN THE AIAG's MSA HANDBOOK OR IN A STATISTICAL OUTPUT
              SOFTWARE
        C. %R&R WITHIN ACCEPTABLE STANDARDS. IF NOT, IS THERE A CORRECTIVE ACTION PLAN
        D.    THREE (3) OPERATORS, THREE (3) TRIALS, 10 PARTS ARE UTILIZED
         E.   ALL GAUGES HAVE THE REQUIRED LEVEL OF RESOLUTION TO EVALUATE CHARACTERISTICS TO SPECIFICATIONS
         F.   GR&R WAS CALCULATED USING THE ANOVA METHOD
        G.    NUMBER OF DISTINCT CATEGORIES (NDC'S) GREATER THAN OR EQUAL TO 5
        H.    FOR ATTRIBUTE GAUGES 50 PIECES MINIMUM (STATISTICAL ANALYSIS INCLUDING KAPPA VALUES SHOULD BE PROVIDED ALSO)
         I.   RAW DATA IS INCLUDED FOR EACH STUDY
         J.   HAS THE GAUGE R&R BEEN CONDUCTED WITHIN THE LAST 1 YEAR

12     Qualified Laboratory Documentation                                                                      R    S   S    *    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   CERTIFICATE OF ACCREDITATION IS FROM A NATIONALLY RECOGNIZED ORGANIZATION
         B.   SCOPE OF ACCREDITATION IS INCLUDED

13     Control Plan                                                                                            R    R   S    *    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   PART NUMBER AND REVISION LEVEL SHOULD MATCH THE DRAWING
         B.   DOES CONTROL PLAN REFLECTS LAUNCH PRACTICE ITEMS
        C. CONTROL PLAN ADDRESSES ALL SIGNIFICANT AND CRITICAL DIMENSIONS/CHARACTERISTICS IDENTIFIED ON THE DRAWING
              OR STANDARDS
        D.    CONTROL PLAN ADDRESSES THE ENTIRE PROCESS FROM RECEIPT OF MATERIAL TO SHIPPING PRODUCT
         E.   CONTROL PLAN INCLUDES ANNUAL REVALIDATION REQUIREMENTS
         F.   CRITICAL FEATURES IDENTIFIED ON THE PCM, BUT NOT ON THE DRAWING (CUSTOMER TOUCH POINTS, CRITICAL PROCESS
              CONTROLS, ETC.) ARE INCLUDED IN THE CONTROL PLAN
        G.    HAVE ALL THE CONTROLS IDENTIFIED IN THE PFMEA BEEN INCLUDED IN THE CP
        H.    WERE DFMEA AND PFMEA USED TO DEVELOP THE CP
         I.   ARE MATERIAL SPECIFICATIONS REQUIRING INSPECTION IDENTIFIED
         J.   ARE ENGINEERING PERFORMANCE TESTING AND DIMENSIONAL REQUIREMENTS IDENTIFIED
         K.   ARE GAUGES AND TEST EQUIPMENT AVAILABLE AS REQUIRED ON THE CP
         L.   ARE THE GAUGE METHODOLOGY AND COMPATIBILITY APPROPRIATE TO MEET TRW'S REQUIREMENTS
        M.    ARE SAMPLE SIZES BASED UPON INDUSTRY STANDARDS, STATISTICAL SAMPLING PLAN TABLES, OR OTHER STATISTICAL 'PROCESS
              CONTROL METHODS OR TECHNIQUES AND REFERRED AS QUANTITIES INSTEAD OF TIME (E.G.., 5/400 INSTEAD OF 5/2 HOURS)
        N.    HAVE THE PROCESS TOLERANCES BEEN ADJUSTED FOR THE ACCURACY OF THE ATTRIBUTE GAUGES
        O.    ARE REACTION PLANS ACCEPTABLE
         P.   IS THE CONTROL PLAN FORMAT IN LINE WITH AIAG REQUIREMENTS

14     Appearance Approval Report                                                                               S   S   S    *    R

15     Bulk Materials Requirement Checklist                                                                    R    R   R    *    R

16     Sample Product                                                                                          R    S   S    *    R

17     Master Sample                                                                                           R    R   R    *    R
         A.   LETTER OF CONFIRMATION THAT MASTER / PPAP SAMPLES ARE RETAINED
18     Checking Aids                                                                                           R    R   R    *    R
         A.   ARE NECESSARY CUSTOMER APPROVALS AVAILABLE FOR CHECKING AID(S) (IF APPLICABLE)
19     Compliance with Customer Specific Requirements                                                          R    R   S    *    R
         A.   DOCUMENT(S) DEMONSTRATING COMPLIANCE WITH ANY OEM SPECIFIC COMMUNICATED REQUIREMENTS.

                                                                                                                                 Additional TRW PPAP Requirements
20     Product Characteristic Matrix (D_020_4_03)                                                               *   *   *    *    *                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   ALL SUB-TIER SUPPLIERS HAVE BEEN INCLUDED BASED ON SUPPLY CHAIN MAP
         B.   ALL SIGNIFICANT AND CRITICAL DIMENSIONS ARE INCLUDED, AND FOLLOW BACK TO THE MANUFACTURING PROCESSES THAT
              PRODUCES THEM
        C.    PFMEA/DFEMA RPN'S ARE LISTED FOR ALL INCLUDED DIMENSIONS/CHARACTERISTICS
        D.    CUSTOMER TOUCH POINTS AND CRITICAL PROCESS CONTROLLED DIMENSIONS ARE INCLUDED
         E.   FOR ANY OF THE IDENTIFIED FEATURES, IF A SUB-TIER SUPPLIER IS RESPONSIBLE FOR THE MANUFACTURE OF THAT FEATURE, THE SAFE
              LAUNCH PLAN SHOULD HAVE ACTIVITIES AT EVERY TIER SUPPLIER THAT HANDLES THAT PART UP TO THE TRW TIER-1 SUPPLIER
         F.   THE PCM HAS THE SIGNATURE OF THE SQA OR THE SQA APPROVAL IS DOCUMENTED (COMPONENTS WITH PRIORITY "A" ONLY)
        G.    THE CHARACTERISTICS MUST HAVE A BALLOON NUMBER (OR GRID) FOR REFERENCE
        H.    DOES THE GAUGE R&R MEET REQUIREMENTS & ACCEPTABLE OR THERE IS A PLAN
         I.   CONTROL EQUIPMENT / METHOD, FREQUENCY, SAMPLE) MATCH WITH CONTROL PLAN
         J.   DOES THE Ppk VALUES MEET GSQM REQUIREMENTS

21     ELV / IMDS                                                                                               *   *   *    *    *                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   THE SUPPLIER IS USING THE CORRECT TRW IMDS NUMBER
        B.    A COPY OF THE SCREEN SHOT HAS BEEN INCLUDED SHOWING A TRW APPROVED IMDS NUMBER

22     Packaging Plan and Sample Label                                                                         R    R   S    *    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   IS THE PACKAGING METHOD INCLUDED AND APPROVED BY TRW
         B.   DOES THE CONTENTS IN LABEL MATCH WITH CONTS IN PSW (PART #, REV, PO #, SHIPPING FROM, TO)
        C.    DOES THE LABELING FORMAT MATCH WITH GSQM REQUIREMENTS / REGIONAL / PL STANDARDS

23     Manufacturing Feasibility Sign-off (D_020_4_16)                                                          *   *   *    *    *
         A.   IS THE COPY SIGNED

24     Capacity Verification (D_020_4_14)                                                                       *   *   *    *    *                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   IS THE RUN @ RATE FORMAT (D_020_4_12_EN ) INCLUDED? (FOR PRIORITY "A" PARTS, THE R @ R MUST BE COMPLETED BY AN
              SDE ON SITE)
         B.   DOES THE SUPPLIER NEED TO INCREASE THEIR CAPACITY
        C.    ARE BOTTLENECKS IDENTIFIED AND RESOLVED
        D.    ARE THERE ANY TOOLING CONSTRAINTS
         E.   WHERE NECESSARY, HAVE EXCEPTION FORMS BEEN SENT TO THE COMMODITY MANAGER

25     Sub - Contractor PPAP status                                                                             S   S   S    S    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   IS THERE A PSW FOR ALL SUBCOMPONENTS OF THE FINAL ASSEMBLY
         B.   ARE THE PSW'S FULLY APPROVED? IF NOT, IS THERE A TRW DEVIATION/CONCESSION FOR EACH PSW NOT FULLY APPROVED

26     Special process approval (Heat treat, Plating, Coating, Anodizing, Welding, Soldering)                   S   S   S    S    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   IS THE EVIDENCE OF THE CQI AUDITS OF THE SPECIAL PROCESSES INCLUDED
         B.   ARE ANODIZING PROCESSES AUDITED ACCORDING TO THE TRW ANODIZING PROCESS CHECKLIST (D_020_4_22)? HAVE AUDITS
              BEEN CARRIED OUT AND ARE THE RESULTS ACCEPTABLE?

27     Certification of Review** (GSQM-151 A11)                                                                 *   *   S    S    R                          COMMENTS      ACTION   RESPONSIBILITY       TARGET DATE
         A.   IS THE CERTIFICATE OF REVIEW INCLUDED IN THE PPAP PACKAGE AND SIGNED AND DATED BY TRW




     Date: 28 May 2010
     Revision: D
     Doc No: D_020_4_19                                                                                                                                                                         Process Owner/Department:
     Page 2 of 29                                                                                               PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls                L. VanDongen / Supplier Development
       Yes                        Y
       No                         N




Date: 28 May 2010
Revision: D
Doc No: D_020_4_19                                                                      Process Owner/Department:
Page 3 of 29         PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
DITIONAL REVIEWS
                                            Approved   R    1 A
           RESULTS                          Rejected   Y    2 B
                                                       G    3 C
                                                       NA   4
                                                            5




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                       Date: 28 May 2010
                       Revision: D
                       Doc No: D_020_4_19                                                                                            Process Owner/Department:
                       Page 4 of 29                               PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
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              Date: 28 May 2010
              Revision: D
              Doc No: D_020_4_19                                                                      Process Owner/Department:
              Page 5 of 29         PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
Date: 28 May 2010
Revision: D
Doc No: D_020_4_19                                                                      Process Owner/Department:
Page 6 of 29         PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
Date: 28 May 2010
Revision: D
Doc No: D_020_4_19                                                                      Process Owner/Department:
Page 7 of 29         PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
Date: 28 May 2010
Revision: D
Doc No: D_020_4_19                                                                      Process Owner/Department:
Page 8 of 29         PPAP Checklist; fd7d642b-01e6-4450-8852-11766e9bc9d9.xls   L. VanDongen / Supplier Development
                                           Table of DFMEA

                                               Criteria:
     Effect                         Severity of Effect on Product
                                         (Customer effect)
Failure to Meet      Potential failure mode affects safe vehicle and/or involves
 Safety and/or      noncompliance with government regulation without warning
  regulatory         Potential failure mode affects safe vehicle and/or involves
Requirements          noncompliance with government regulation with warning
                  Loss of primary function (vehicle inoperable, does not affect safe
     Loss or
                                          vehicle operation)
 Degradation of
                 Degradation of primary function (vehicle operable but at a reduced
primary function
                                        level of performance)
     Loss or         Loss of secondary function (vehicle operable, but comfort/
 Degradation of                   convenience functions inoperable)
   secondary        Degradation of secondary function (vehicle operable but at a
    function                        reduced level of performance)
                   Appearance or audible Noise, vehicle operable, item does not
                          conform and noticed by most customers (>75%)
                   Appearance or audible Noise, vehicle operable, item does not
   Annoyance
                          conform and noticed by many customers (>50%)
                   Appearance or audible Noise, vehicle operable, item does not
                     conform and noticed by discriminating customers (>25%)
    No effect                            No discernible effect



Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
              Rank


               10

                9

                8

                7

                6

                5

                4

                3

                2
                1



the AIAG 4th Edition
 Likelihood of    Criteria: Occurrence of cause-DFMEA (design life/reliability of
    failure                                item/vehicle)



   Very High                  New technology/new Design with no history

                  Failure is inevitable with new design, new application, or change in
                                     duty cycle/operating conditions.

                  Failure is likely with new design, new application, or change in duty
     High                                cycle/operating conditions.


                  Failure is uncertain with new design, new application, or change in
                                    duty cycle/operating conditions.

                    Frequent failures associated with similar designs or in design
                                        simulation and testing
   Moderate        Occasional failures associated with similar designs or in design
                                         simulation and testing
                    Isolated failures associated with similar designs or in design
                                         simulation and testing
                  Only isolated failures associated with almost identical design or in
                                      design simulation and testing
      Low
                  No observed failures associated with almost identical design or in
                                    design simulation and testing


    Very low                Failure is eliminated through preventive control



Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
               Criteria: Occurrence
                                        Rank
                of cause-DFMEA


               >= 100 per Thousand
                                         10
                    >= 1 in 10
                  50 per Thousand
                                         9
                       1 in 20

                  20 per Thousand
                                         8
                       1 in 50


                  10 per Thousand
                                         7
                      1 in 100

                  2 per Thousand
                                         6
                      1 in 500
                  0.5 per Thousand
                                         5
                       1 in 2,000
                  0.1 per Thousand
                                         4
                      1 in 10,000
                0.01 per Thousand
                                         3
                     1 in 100,000
                     <= 0.001 per
                      Thousand           2
                    1 in 1,000,000
                Failure is eliminated
                 through preventive      1
                         control


the AIAG 4th Edition
Opportunity for
  Detection

 No detection
 Opportunity
 Not likely to
 detect at any
    stage




  Post Design
Freeze and Prior
   to launch




Prior to Design
    Freeze




Virtual Analysis -
   Correlated

 Detection not
  applicable;
    Failure
  Prevention


Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Ed
                                         Criteria:                                             Likelihood
                                                                                       Rank
                        Likelihood of detection by Design Control                             of Detection

                                                                                                Almost
                No current design control; Cannot detect or is not analyzed             10
                                                                                              Impossible
            Design analysis/detection controls have a weak detection capability;
                                                                                                 Very
            Virtual Analysis (e.g. CAE, FEA, etc..) is not correlated to expected       9
                                                                                                Remote
                                  annual operating conditions
            Product verification/validation after design freeze and prior to launch
            with pass/fail testing (Subsystem or system testing with acceptance         8       Remote
                criteria such as ride and handling, shipping evaluation, etc..).

            Product verification/validation after design freeze and prior to launch
            with test to failure testing (Subsystem or system testing until failure     7      Very low
                         occurs, testing of system interactions, etc..).
            Product verification/validation after design freeze and prior to launch
              with degradation testing (Subsystem or system testing durability          6        Low
                                    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..)
               Product validation (reliability testing, development or validation
                                                                                              Moderately
             tests) prior to design freeze using test to failure (e.g., until leaks,    4
                                                                                                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
                  capability. Virtual analysis (e.g., CAE, FEA, etc.) is highly
                                                                                        2      Very high
              correlated with actual or expected operating conditions prior to
                                            design freeze.
              Failure cause or failure mode can not occur because it is faulty
                                                                                                Almost
             prevented through design solutions (e.g., proven design standard,          1
                                                                                                Certain
                          best practice or common material, etc.)



d on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
                                               Criteria:
     Effect                         Severity of Effect on Product
                                         (Customer effect)
Failure to Meet       Potential failure mode affects safe vehicle and/or involves
 Safety and/or       noncompliance with government regulation without warning
  regulatory          Potential failure mode affects safe vehicle and/or involves
Requirements           noncompliance with government regulation with warning
                   Loss of primary function (vehicle inoperable, does not affect safe
     Loss or                               vehicle operation)
 Degradation of
primary function Degradation of primary function (vehicle operable but at a reduced
                                       level of performance)
     Loss or        Loss of secondary function (vehicle operable, but comfort/
 Degradation of                 convenience functions inoperable)
   secondary       Degradation of secondary function (vehicle operable but at a
    function                       reduced level of performance)
                   Appearance or audible Noise, vehicle operable, item does not
                         conform and noticed by most customers (>75%)
                   Appearance or audible Noise, vehicle operable, item does not
   Annoyance
                         conform and noticed by many customers (>50%)
                   Appearance or audible Noise, vehicle operable, item does not
                     conform and noticed by discriminating customers (>25%)
    No effect                           No discernible effect


Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
                                                                        Criteria:
                 Rank        Effect                          Severity of Effect on Process
                                                           (Manufacturing/Assembly Effect)
                        Failure to Meet
                  10
                         Safety and/or       May endanger operator (machine or assembly) without warning
                   9      regulatory
                        Requirements           May endanger operator (machine or assembly) with warning
                             Major          100% of product may have to be scrapped. Line shutdown or stop
                   8
                          disruptions                                        ship
                                           A portion of the production may have to be scrapped. Deviation from
                          Significant
                   7                            primary process including decreased line speed or added
                          disruptions
                                                                          manpower
                                              100% of production run may have to be reworked off line and
                   6
                           Moderate                                       accepted
                           disruption      A portion of the production run may have to be reworked off line and
                   5
                                                                          accepted
                                           100% of production run may have to be reworked in station before it
                   4
                           Moderate                                     is processed
                           disruption       A portion of the production run may have to be reworked in station
                   3
                                                                   before it is processed
                   2    Minor disruption
                                                 Slight inconvenience to process, operation, or operator.
                   1       No effect                              No discernible effect


the AIAG 4th Edition
 Likelihood of        Criteria: Occurrence of cause-PFMEA (incidents per
    failure                             items/vehicles)

                                       >= 100 per Thousand
   Very High
                                            >= 1 in 10
                                         50 per Thousand
                                              1 in 20
                                         20 per Thousand
     High
                                              1 in 50
                                         10 per Thousand
                                             1 in 100
                                          2 per Thousand
                                              1 in 500
   Moderate                                0.5 per Thousand
                                                1 in 2,000
                                           0.1 per Thousand
                                              1 in 10,000
                                          0.01 per Thousand
                                              1 in 100,000
      Low
                                         <=0.001 per Thousand
                                             1 in 1,000,000
    Very low               Failure is eliminated through preventive control


Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
                 Rank


                   10

                   9

                   8

                   7

                   6

                   5

                   4

                   3

                   2
                   1


the AIAG 4th Edition
90
     Opportunity for
       Detection

       No detection
       Opportunity
       Not likely to
       detect at any
           stage
         Problem
      detection post
        processing
        Problem
       detection at
         source

         Problem
      detection post
       processing


        Problem
       detection at
         source

        Problem
     detection post
       processing
        Problem
      detection at
         source
     Error Detection
     and/or problem
       Prevention
      Detection not
     applicable; Error
       Prevention




     Based on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Ed
                                        Criteria:                                                Likelihood
                                                                                         Rank
                       Likelihood of detection by Process Control                               of Detection

                                                                                                  Almost
                No current process control; Cannot detect or is not analyzed              10
                                                                                                Impossible
               Failure Mode and/or error (Cause) is not easily detected (e.g.,                     Very
                                                                                          9
                                      random audits)                                              Remote

                Failure Mode detection post-processing by operator through
                                                                                          8       Remote
                               visual/tactile/audible means
                    Failure Mode detection in-station by operator through
               visual/tactile/audible means or post-processing through use of
                                                                                          7      Very low
             attribute gauging (go/no-go), manual torque check/clicker wrench,
                                            etc.)
             Failure Mode detection post-processing by operator through use of
              variable gauging or in-station by operator through use of attribute         6        Low
               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 controls in-station
            that will detect discrepant part and notify operator light, buzzer, etc.).    5      Moderate
                Gauging performed on set-up and first piece check (for set-up
                                         causes only)
             Failure Mode detection post-processing by automated controls that
                                                                                                Moderately
                  will detect discrepant part and lock part to prevent further            4
                                                                                                  High
                                          processing
              Failure Mode detection in-station by automated controls that will
                                                                                          3        High
              detect discrepant part and lock part to prevent further processing

              Error (Cause) detection in-station by automated controls that will
                                                                                          2      Very high
                 detect error and prevent discrepant part from being made.

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




d on the Potential Failure Mode and Effect Analysis Manual from the AIAG 4th Edition
                                                        Special Characteristics Procedur
          TRW Product Line                TRW Region



                                          Global

Braking, Linkage & Suspension, Steering

                                          Brazil



                                          North
                                          America

                                          Electronics
                                          (North
                                          America)

       Occupant Safety Systems



                                          Europe




                                          North
     Commercial Steering Systems
                                          America



                    PLEASE NOTE: THE DOCUMENTS LISTED AB
      TO ACCESS CONTROLLED DOCUMENTS, PLEASE REFER TO TH
                                          (http://vin.livmi.tr
         Special Characteristics Procedures by PL and Region
           Document Name                        Document Number


        Designated
                                   GSQM-100A                   GSQM_100A
        Characteristics List


        Identificação de
                                   GSQM_100A-Brazil         GSQM_100A_Brazil.
        Desenhos (Informativo)                                    doc


        Designated
        Characteristics Standard   WA.C45.001               WA_C45_001.doc
        Procedure

        Designated
                                   GSQM-101                   GSQM_101.xls
        Characteristics


        Special Characteristics
        Implementation             GSQM-OSS 20.30G           GSQM_OSS_20-
        Procedure                                               30G.doc


        Special Characteristics
        Classification, Labeling of GSQM-OSS 20.30F
                                                             GSQM_OSS_20-
        Characteristics                                         30F.doc


        Designated
        Characteristics Standard   CSS192239                 CSS192239.doc
        Procedure


NOTE: THE DOCUMENTS LISTED ABOVE ARE FOR REFERENCE ONLY.
DOCUMENTS, PLEASE REFER TO THE TRW GLOBAL SUPPLIER QUALITY MANUAL (GSQM)
               (http://vin.livmi.trw.com/)
                     Description


        Defines special characteristics used
        on drawings.




        Defines special characteristics used
        on drawings.


        Designates symbols used in
        additional to WA.C45.001


        Defines purpose and procedure for
        implementing special characteristics
        used on drawings.


        Special characteristics classifications
        and labeling.



        Defines critical and significant
        characteristics



 ENCE ONLY.
PLIER QUALITY MANUAL (GSQM)
Interpreting Gage R&R: Minitab’s Graphical
               Should be small relative to part-to-                                                                        Gage name:                       Differe
                                                                                                                                                Opacity Meter
                                                                                                                           Date of study:       8/19/01
             Gage R&R (ANOVA) for Measurement
               part if measurement system is                                                                               Reported by:         GRR
                                                                                                                                                            values
               good
                                                                                                                           Tolerance:
                                                                                                                           Misc:
                                                                                                                                                4
                                                                                                                                                            part va
                                             Components of Variation                                                                  By Unit Number
                                100
                                                                                            %Contribution             13
                                                                                            %Study Var
             Percent
                                                                                            %Tolerance
                                50                                                                                    12



                                 0                                                                                    11
                                          Gage R&R   Repeat     Reprod   Part-to-Part                   Unit Number 1                 2            3            4

                                                R Chart by Operator                                                                         By Operator
                                                          Joe                  Sally
                                0.2                                                     UCL=0.2053
              Sample Range




                                                                                                                      13


                                0.1                                                     R=0.09                        12


                                0.0                                                     LCL=0
                                                                                                                      11
                                      0                                                                     Operator Joe                                            Sa

                                              Xbar Chart by Operator                                                       Operator*Unit Number Interactio
                                                          Joe                  Sally
                                                                                                                      13
                  Sample Mean




                                13




                                                                                                            Average
                                12                                                      UCL=12.09
                                                                                        Mean=12.02                    12
                                                                                        LCL=11.96


                                11                                                                                    11
                                      0                                                                 Unit Number           1             2          3        4

                                                                    For good measurement
        Should always be
                                                                    systems, this will be
        in control, meaning                                                                                                                                         P
                                                                    out of control,
        the operators                                                                                                                                               l
                                                                    indicating the parts are
        consistently                                                                                                                                                i
                                                                    more variable than the
        measure the same
                                                                    measurement system
        way. If not, identify
                                                                    (which is good)
        special cause.



                                                                                          Taken from the TRW's Measurement System
                                                                                                 from the Green Belt Refresher Traini
’s Graphical Output                                                     Interpreting the Gag
                                        Difference in
                                                                        Output From Minita
       Gage name:           Opacity Meter
       Date of study:       8/19/01
       Reported by:         GRR
                                        values is part-to-
       Tolerance:
       Misc:
                            4
                                        part variation
                                                                                      Gage R&R
                  By Unit Number
3                                                                                     Source

2                                                                                     Total Gage
                                                                                        Repeatab
1                                                                                       Reproduc
mber 1            2            3            4    5
                                                                                          Operat
                        By Operator                       Difference                  Part-To-Pa
3                                                         in                          Total Vari
                                                          horizontal                             A
2
                                                          alignment                   %Tolerance
1
                                                          is operator                 Source
ator Joe                                        Sally
                                                          effect                      (SV/Toler)
       Operator*Unit Number Interaction
                                                        Operator
3                                                           Joe                       Total Gage
                                                            Sally
                                                                                        Repeatab
2                                                                                       Reproduc
                                                                                          Operat
1                                                                                     Part-To-Pa
mber       1            2          3        4    5
                                                                                      Total Vari
nt
                                                                                     These will
                                                Parallel                                Number of
                                                                                     match
                                                lines if no                          when there
e
                                                interaction                          is no
e
                                                                                     operator
                                                                                     part
                                                                                     interaction




he TRW's Measurement System Validation Class
he Green Belt Refresher Training Material
eting the Gage R&R
 From Minitab, Cont.                     Total Gage
                                          R&R plus
                                         Part-To-Part
                                           equals
                                            100%
       Gage R&R
                                                    %Contribution
       Source                            VarComp    (of VarComp)         Should give the
                 A2+A3 =
                                                                         width of 99%
       Total Gage R&R               A1   0.00705      1.26               confidence
         Repeatability              A2   0.00183      0.33               interval
         Reproducibility            A3   0.00521      0.94
           Operator                 A4   0.00521      0.94
       Part-To-Part                      0.55042     98.74                         Will not
                                    A5                        = 5.15 x st. dev.    sum to
       Total Variation              A6   0.55747    100.00
                                                                                    100
                  A2+A3 +A5=
                                         StdDev         Study Var   %Study Var
       %Tolerance
       Source                  m        (SD)           (5.15*SD)   (%SV)
       (SV/Toler)

       Total Gage R&R                    0.083950       0.43234      11.24           10.81
         Repeatability                   0.042835       0.22060       5.74            5.52
         Reproducibility                 0.072199       0.37183       9.67            9.30
           Operator                      0.072199       0.37183       9.67            9.30
       Part-To-Part                      0.741905       3.82081      99.37           95.52
       Total Variation         p        0.746640       3.84519     100.00           96.13

      These will                                          %R&R                    %P/T
         Number of Distinct Categories = 12
      match
      when there
      is no
      operator
      part                         Should be 5 or more for a
      interaction                  healthy measurement system
 ould give the
dth of 99%
nfidence
erval

        Will not
v.      sum to
         100
y Var




4         10.81
4          5.52
7          9.30
7          9.30
7         95.52
0         96.13

     %P/T

				
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