Cooper_Industries_PPAP_Form_Kit

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                                    PPAP                                                                    Submission Requirements                                                                                    Submission Level
                        Production Part Approval Process                                                       Supplier Checklist                                                                                       (Please Type 1-5)       3
                      Cooper Part Number                                                                  Part Description                                                             Supplier Name
                           Revision Level                                                          Cooper Purchasing Rep.                                                            Submission Date
           Primary Manufacturing Site                                                              Purchasing Rep Phone #                                                             PPAP Due Date

             PPAP Requirements




                                                                                                                                                                                                                                                Included
 Element




             AIAG PPAP Fourth Edition
                                            Level 1
                                                      Level 2
                                                                Level 3
                                                                          Level 4
                                                                                    Level 5
 Order




                Important: Submit your
               documents in this order.                                                           Required Documents                       Assigned to                        Internal Due Date               Comments/Concerns/Questions

   1
           Part Submission Warrant                                        AR                  Cooper PSW Required                                                                                                                               YES
           (PSW)


   2
           Design Records &                                               AR
                                                                                              TWO Cooper Divisional Parts
                                                                                                                                                                                                                                                YES
           Bubbled part print(s).                                                             Prints



   3
           Approved Engineering                                           AR        AR
                                                                                              Various engineering
           Change Documentation                                                               documentation                                                                                                                                     YES




   4
           Customer Engineering                                                               Not Required for Cooper
           Approvals                                                                          Submissions                                                                                                                                       YES




   5
                                                                                              Can be Cooper FMEA Format or
           Design FMEA,                                         AR        AR        AR
                                                                                              an AIAG compliant DFMEA.                                                                                                                          YES




   6       Process Flow Diagrams                                          AR                  Any standard flowchart format.                                                                                                                    YES




   7
                                                                                              Can be Cooper PFMEA Format
           Process FMEA                                                   AR
                                                                                              or an AIAH compliant PFMEA.                                                                                                                       YES




   8
                                                                                              Can be Cooper supplied format
           Control Plan                                                   AR
                                                                                              or AIAG compliant format.                                                                                                                         YES


                                                                                              Cooper GRR format or any
   9
           Measurement System                                                                                                                                                                                                                   YES
                                                      AR                  AR                  statistical package format for
           Analysis Studies                                                                   gage R&R.


   10
                                                                                              Must be on Cooper Dimensional
           Dimensional Results                                            AR
                                                                                              report format
                                                                                                                                                                                                                                                YES



                                                                                              Industry Standard reports or test
   11
           Material, Performance                      AR                  AR                  result formats designated by                                                                                                                      YES
           Test Results                                                                       Cooper Industries.

           Initial Process Study                                                              Process Capability Study using
   12      (Cpk)                                      AR                  AR                  any statistical package or                                                                                                                        YES
           Capability Studies                                                                 Cooper Capability Data Forms.


   13
           Qualified Laboratory                                           AR
                                                                                              Lab Scope and outside lab proof
           Documentation                                                                      of accreditation.                                                                                                                                 YES




   14
           Appearance Approval              AR        AR        AR        AR        AR        AIAG format AAR                                                                                                                                   YES
           Report


   15
                                                                                              Parts tagged in accordance with                                                                                                                   YES
           Sample Product Parts                                           AR
                                                                                              Cooper PPAP reference manual



   16      Master Samples                                                                     Required only for level 5                                                                                                                         YES




   17
                                                                                              Checking aid design prints and
           Checking aids                                                  AR
                                                                                              GRR for checking fixtures.
                                                                                                                                                                                                                                                YES




   18
           Customer Specific                                                                  Documents as specified by
           Requirements                                                                       Cooper Industries


                                                                                                                                                                                                                                                YES
   a
                                                                                              Specific document required by
           Tooling Information Form                                       AR
                                                                                              Cooper Industries.


                                                                                                                                                                                                                                                YES
   b
                                                                                              Specific document required by
           Packaging Form                                                 AR
                                                                                              Cooper Industries.


   c       Inspection Plan                             IA        IA        IA        IA       Specific ASC Format                                                                                                                           e
                                                                                                                                                                                                                                                YES
           (ASC Suppliers only)


                                                                                                                                                                                                                                                YES
   d
           Specification Deviation                     IA        IA        IA        IA
                                                                                              Specific document required by
           Form                                                                               Cooper Industries.


                                                                                                                                                                                                                                                YES
   e
                                                                                              Specific document required by
           Supplier PPAP Checklist                                        AR
                                                                                              Cooper Industries.


Required for PPAP submission                          Not required                                       Documents on a case by case basis are marked AR for "As Requested"               AR           IF Applicable    IA
                                                                                                                                                    Part Submission Warrant
         Part Name                                                                                                               Cooper Part Number

         Safety and/or
         Government Regulation            Yes             No                                Engineering Drawing Revision Level                                                 Dated


         Additional Engineering Changes                                                                                                                                        Dated


         Shown on Drawing Number                                                                                     Purchase Order No.                                    Weight (kg)


         SUPPLIER MANUFACTURING INFORMATION                                                                          SUBMISSION INFORMATION



         Supplier Company Name                     Supplier Vendor Number                                            Customer Name:



         Additional Manufacturing Sites                                                                              Cooper Manufacturing Locations using the part (list all)


         Street Address                                                                                              Purchasing Representative                                           Purchasing Office



         City                             State                          Zip                                         PPAP Due Date:                                          SOP Date



         Does this part utilize Cooper owned tooling? Is it properly identified?                                         Yes          No                      If yes, P.O. #


         Does this part contain any restricted substances or require IMDS submission?                                    Yes          No                      Substance(s)?

                                                                                                                                                                 IMDS Number
         Are plastic or polymeric parts identified with appropriate ISO marking codes?                                   Yes          No

         REASON FOR SUBMISSION
                 Initial submission (New Parts and Part Number Changes)                                                                New Supplier, New material or new source for existing material
                 Engineering Change: New/Revised drawing or other specification                                                        Change of supplier, material or non-equivalent materials/services
                 Tooling: transfer, replacement (new), refurbishment, modified or additional                                           New process or a change in production process or method
                 Correction of Non-conformance or discrepancy                                                                          Change of manufacturing location, sub-supplier or additional location
                 Change to optional construction, material or component                                                                Other - please specify


         REQUESTED SUBMISSION LEVEL (Check one)
                 Level 1 - Warrant only submitted to the customer (Applied to non-critical parts and raw bulk material)
                 Level 2 - Warrant with product samples amd limiting supporting data. (Applied to critical bulk product and simple changes)
                 Level 3 - Warrant with product samples and complete supporting data. (Applied to new parts on Cooper programs)                    DEFAULT COOPER SUBMISSION LEVEL
                 Level 4 - Warrant and other requirements as defined by Cooper.(Applied only with prior approval from Cooper…special situations only!)
                 Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. (Applied to parts requiring onsite review )


         SUBMISSION RESULTS
         The results for                        dimensional measurements                    material and functional tests               appearance criteria                  statistical process package

         These results meet all drawing and specification requirements:               YES        NO                   (If "NO" - Explanation Required in Explanation/comments section below )

         Is this a multicavity tool?      YES        NO         How many Cavities/Spindle (for molds or dies) ?                  Number of parts submitted by cavity/spindle


         DECLARATION
         I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 4th Edition
         requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regular production
         process. The data and samples were produced at the production rate of                                  in               on               Any deviations to this warrant submission
         are noted below in the explanation/comments section.                                  #parts                 # hours          date


         EXPLANATION/COMMENTS:



         Print Name:                                                  Job Title                                                               Phone No.                      Fax No.


         Supplier Authorized Signature                                                                                                 Date                        Email

                                                                                 FOR COOPER INDUSTRIES USE ONLY

                                          Quality/Supplier Quality                                                                                                  Date
Initial Part Warrant Disposition:
                                          Quality/Supplier Quality Management                                                                                       Date
    Interim      Expires:

Final Part Warrant Disposition:
                                                   Quality or Supplier Quality                                                                                      Date
     Approved               Rejected

                            Print Approver Name:                                                                                       Cooper PPAP Tracking Number:
                                                                                                                            Control Plan
Control Plan Number                                Key Contact / Phone                                                           Date (Orig.)         Current Release Level                 Current Release Date

Part Number/ Latest Change (Rev) Level                    Part Description                                                                            Supplier Code                         Plant Location

Core Team                                                                            Supplier Name                                                    Quality Department Approval



Customer Engineering Approval / Date (If Req'd)                                      Supplier Plant Approval                                          Other Approval / Date (If Req'd)




                                                                             CHARACTERISTICS                                                           METHODS
PROCESS




                                                                                                                                                                               SAMPLE
NUMBER
PART /




          PROCESS NAME /   MACHINE DEVICES / JIG                                                                      SPECIAL    PRODUCT / PROCESS        EVALUATION/




                                                                                                                                                                                     FREQ
                                                                                                                                                                              SIZE
            OPERATION         / TOOLS FOR                                                                              CHAR.      / SPECIFICATION /      MEASUREMENT
                                                   NO.           PRODUCT                       PROCESS
            DESCRIPTION      MANUFACTURING                                                                             CLASS         TOLERANCE             TECHNIQUE                             CONTROL METHOD    REACTION PLAN




                                                         Note: All part print CTQ's must be clearly identified on this control plan.                                                                                               Page 6 of 28
Note: All part print CTQ's must be clearly identified on this control plan.   Page 7 of 28
                                                                                                                                                                                                  Page 8 of 28

                                                                                                                                        Please indicate EITHER:
                                                        Potential Failure Modes and Effects Analysis                                    1.) A designated RPN threshold for this process
                                                                                                                                        2.) A target percentage of steps to be addressed.
                                                                        Design FMEA                                                                                                 Check One

Print #                                                              Design Responsibility                                                              FMEA Number
Item Name                                                            Contact Number                                                                       Prepared By
Rev #                                                                Key Date                                                                         FMEA Date (Orig.)
Core Team                                                            Customer Manufacturing Site                                                           FMEA Date



                                                                         C                               Current Product Controls                                                    Action Results
Item Number




                                                                                                                                                         Responsibility
                                                                       S l                           O                              D R
                Item/                     Potential  Potential Effects         Potential Cause(s)/                                      Recommended          and
                         Requirements                                  E a                           C                              E P                                                               S O D R
              Function                  Failure Mode    of Failure             Failure Mechanisms                                         Action(s)       Completion
                                                                       V s                           C   Prevention    Detection    T N                                        Actions Taken          E C E P
                                                                                                                                                             Date
                                                                         s                                                                                                                            V C T N
                                                                                                                                                                                                          Page 9 of 28

                                                                                                                                                Please indicate EITHER:
                                                             Potential Failure Modes and Effects Analysis                                       1.) A designated RPN threshold for this process
                                                                                                                                                2.) A target percentage of steps to be addressed.
                                                                             Design FMEA                                                                                                    Check One

Print #                                                                      Design Responsibility                                                              FMEA Number
Item Name                                                                    Contact Number                                                                       Prepared By
Rev #                                                                        Key Date                                                                         FMEA Date (Orig.)
Core Team                                                                    Customer Manufacturing Site                                                           FMEA Date



                                                                               C                                 Current Product Controls                                                    Action Results
Item Number




                                                                                                                                                                 Responsibility
                                                                             S l                             O                              D R
                   Item/                     Potential   Potential Effects             Potential Cause(s)/                                      Recommended          and
                             Requirements                                    E a                             C                              E P                                                               S O D R
                 Function                   Failure Mode     of Failure                Failure Mechanisms                                         Action(s)       Completion
                                                                             V s                             C   Prevention    Detection    T N                                        Actions Taken          E C E P
                                                                                                                                                                     Date
                                                                               s                                                                                                                              V C T N




              PLEASE NOTE: ZOOM LEVEL MUST BE AT 100% TO
              READ LARGE COMMENT FRAMES.


              Please delete this text box after reading.
Page 10 of 28
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                                                                                                                                                                                                                  Page 12 of 28

                                                                                                                                                   Please indicate EITHER:
                                                                Potential Failure Modes and Effects Analysis                                       1.) A designated RPN threshold for this process
                                                                                                                                                   2.) A target percentage of steps to be addressed.
                                                                                Process FMEA                                                                                                   Check One

Print #                                                                         Process Responsibility                                                             FMEA Number
Item Name                                                                       Contact Number                                                                       Prepared By
Rev #                                                                           Key Date                                                                         FMEA Date (Orig.)
Core Team                                                                       Customer Manufacturing Site                                                           FMEA Date



                                                                                                                    Current Process Controls                                                    Action Results
Process Number




                                                                                  C
                                                                                                                                                                    Responsibility
                                                                                S l                             O                              D R
                 Process/Step                   Potential   Potential Effects             Potential Cause(s)/                                      Recommended          and
                                Requirements                                    E a                             C                              E P                                                               S O D R
                   Function                    Failure Mode     of Failure                Failure Mechanisms                                         Action(s)       Completion
                                                                                V s                             C   Prevention    Detection    T N                                        Actions Taken          E C E P
                                                                                                                                                                        Date
                                                                                  s                                                                                                                              V C T N
                                                                                                                                                                                                                  Page 13 of 28

                                                                                                                                                   Please indicate EITHER:
                                                                Potential Failure Modes and Effects Analysis                                       1.) A designated RPN threshold for this process
                                                                                                                                                   2.) A target percentage of steps to be addressed.
                                                                                Process FMEA                                                                                                   Check One

Print #                                                                         Process Responsibility                                                             FMEA Number
Item Name                                                                       Contact Number                                                                       Prepared By
Rev #                                                                           Key Date                                                                         FMEA Date (Orig.)
Core Team                                                                       Customer Manufacturing Site                                                           FMEA Date



                                                                                                                    Current Process Controls                                                    Action Results
Process Number




                                                                                  C
                                                                                                                                                                    Responsibility
                                                                                S l                             O                              D R
                 Process/Step                   Potential   Potential Effects             Potential Cause(s)/                                      Recommended          and
                                Requirements                                    E a                             C                              E P                                                               S O D R
                   Function                    Failure Mode     of Failure                Failure Mechanisms                                         Action(s)       Completion
                                                                                V s                             C   Prevention    Detection    T N                                        Actions Taken          E C E P
                                                                                                                                                                        Date
                                                                                  s                                                                                                                              V C T N




PLEASE NOTE: ZOOM LEVEL MUST BE AT 100% TO
READ LARGE COMMENT FRAMES.


Please delete this text box after reading.
Page 14 of 28
Page 15 of 28
                                                                                                                                                                                                                                                      Date of Measurement:

                                                                                                                                             DIMENSIONAL DATA SHEET                                                                                          Page #:                   of
                                                                         Reason for Data Submission (check all that apply):                                                                Supplier Representative:                                           Supplier Signature
Supplier Name:

Part Name:                                                                     Initial submission                                   New/revised item, material or product component        Name                           Title
                                                                                                                                                                                                                                                                                   Judgement Legend
Part Number                                                                  Correction of Non-conformance                          New Supplier

Drawing Number:                                                              New/Revised drawing or other specification             New or significantly modified process or routing       Phone Number                   Email:                              OK         Meets Requirements

Revision Level:                                                              Change to optional construction or material            Change of location, sub-supplier or material                                                                              OKNI       OK But Needs Improvement

Revision Date:                                                                Tooling: Transfer, replacement, refurbishment         Other - please specify                                 Date:                          Supplier Code:                      NG         Does Not Meet Requirements
                                                                             or additional tool.
                      A=Attribute




                                                                                                                                                                                                                                                                   Judgement
                      V=Variable




                                                                                                                                                                                       Data for Sample Number…..
          Cpk (Y/N)

                      Data Type:
          Required




                                                                                                          Bonus
 ITEM #




                                      REQUIREMENT:         Measurement      REQUIREMENT:
                                                                                                          Applied             Min      Max                                                                                                                                                  Comments/Action Plan
                                    Description of Check     Method            Target
                                                                                                           (Y/N)
                                                                                                                                                       1           2               3   4      5        6        7     8       9       10   Average   Range    Supplier



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                                                                                                                           NOTE: Any out of specification data will require corrective action.
                                                         Supplier Change Request
                                              This approved form must accompany your PPAP submission
Supplier Information

   Supplier Name                                                                 Date of Request
   Supplier Number                                                               Cooper Purchasing Contact
   Supplier Location(s)                                                          Supplier Contact Name
                                                                                 Supplier Contact Phone #
                                                                                 Supplier Contact Email

                 Date of Proposed FUTURE Change

                 Description of Change (Please describe in detail the nature of the change)




                            This section is reserved for parts sourced through CES (Cooper Electric Shaghai)
CES Product?         Yes      No                                          Name of CES SQE

Customer Information: (Please list additional part numbers on a separate sheet if necessary)
                       Customer Part Number(s) Affected                               Customer Location(s) Affected (city,state)




Type of Change                  (Note:) You are required to notify and receive approval from Cooper for any of these types.
  (Select One)                           Designations in ( ) are the recommend PPAP Level submissions for this type of change

    1. Change to construction, material or component (L3)                            7. Product/process changes on components of the product (L4)
    2. New, additional or modified tools (L3)                                        8. Change in test or inspection method (L4)
    3. Upgrade or rearrangement of existing tools (L2)                               9. Bulk Material: New source of raw material (L2)
    4. Tooling, production or equipment transferred to different site (L3)           10. Change in product appearance attributes (L2)
    5. Change of supplier or non-equivalent materials/services (L3)                  11. Change in production process or method (L4)
    6. Product when tooling has been inactive for 12 months (L2)                     12. Change of Sub Supplier or material source (L3)

                           Reference: Section 3 Table 3.1 on Page 13 of AIAG PPAP 4th edition (May 2006)
                                      ALL Information Below is to be filled out by Cooper Industries.
Cooper Requirements (Plant Quality, Supplier Quality and Puchasing)
  Purchasing
  Timing Plan Received     Yes                   No                                  Date SCR Received

   Quality or Supplier Quality
   PPAP Required?             Yes                       No                           Level                                   Due Date

   Process Audit               Yes                      No                           Engineering Consulted
                                                                                                                             Engineer      Date
   Additional Requirements




Approval Signatures                                     Signature                                                        Date
   Purchasing Representative

   Quality Representative
                     Mandatory Distribution: Plant Operations, Plant Quality, Purchasing, Supplier Quality and Engineering
                                                                                                                                               Page 18 of 28

                                                                                                  Cooper Tooling reference number.
                                Tooling Information Form                                                   (if applicable)
                                                                                                                                                    XXXXX

Supplier Name                   PPAP Submission Level         Affected Feature Number(s)          Part Description

Date      PPAP Due Date         Part Number                            Tool Location
                                                                Facility
Date of Tooling Change          Part Name                      Machine
                                                                Station
   New Tooling           Modified Tooling            Required for PPAP             Note: This document must be completed for all Cooper owned tooling.



                                              Complete Supplier Tooling Action Item List to ensure all items are completed.
TOOLING ACTION ITEMS                          Who                            What                         When                           Status
Tooling Images
Diagram or Strip Layout
Tool Drawings
Tool Cost Breakdown
                 Design Cost
                Material Cost
                  Labor Cost
Tool Description
Tool Dimensions
                      Length
                       Width
                      Height
            Daylight Opening
                      Weight
Press Size
Tool Material
Tool Capacity
                      Hourly
                        Daily
                      Annual
Life Expectancy

Comments
                                                                                                                                                  Page 19 of 28

                                                                                                     Cooper Tooling reference number.
                             Tooling Information Form                                                         (if applicable)
                                                                                                                                                       XXXXX

Supplier Name                  PPAP Submission Level             Affected Feature Number(s)          Part Description

Date      PPAP Due Date        Part Number                                Tool Location
                                                                   Facility
Date of Tooling Change         Part Name                          Machine
                                                                   Station
   New Tooling           Modified Tooling               Required for PPAP             Note: This document must be completed for all Cooper owned tooling.


          Fig. 1                            Top View                         Fig. 2                            Bottom View




          Fig. 3                            Left View                        Fig. 4                              Right View
                                                                                                                                                   Page 20 of 28

                                                                                                      Cooper Tooling reference number.
                             Tooling Information Form                                                          (if applicable)
                                                                                                                                                        XXXXX

Supplier Name                  PPAP Submission Level              Affected Feature Number(s)          Part Description

Date      PPAP Due Date        Part Number                                 Tool Location
                                                                    Facility
Date of Tooling Change         Part Name                           Machine
                                                                    Station
   New Tooling           Modified Tooling                Required for PPAP             Note: This document must be completed for all Cooper owned tooling.


          Fig. 5                            Front View                        Fig. 6                              Back View




          Fig. 7                       Tool Tag View                          Fig. 8                               Example
                                                                                                                                             Page 21 of 28

                                                                                                Cooper Tooling reference number.
                             Tooling Information Form                                                    (if applicable)
                                                                                                                                                  XXXXX

Supplier Name                  PPAP Submission Level        Affected Feature Number(s)          Part Description

Date      PPAP Due Date        Part Number                           Tool Location
                                                              Facility
Date of Tooling Change         Part Name                     Machine
                                                              Station
   New Tooling           Modified Tooling          Required for PPAP             Note: This document must be completed for all Cooper owned tooling.


Additional Comments
                                                                     Packaging Form
Date                                         Packaging Contact              Part Number                                Supplier Responsibilities Completed?
                                                                                                                                  Packaging Design
Supplier Name                                Phone Number                   Print Revision Level                                    Packaging that prevents
                                                                                                                                    shipping and material
Supplier Code                                Fax Number                     Part Description                                        handling defects
                                                                                                                                    Electronic storage of
Supplier Production Facility                 E-Mail Address                 HAZMAT?                                                 submitted Packaging Data
                                                                                                                                    Form


                                Part                         In Packaging Position                         Container                         With Label Shown
  DIGITAL IMAGES




                   Component                 L (mm)   W (mm) H (mm) Component                              Wt (kg)                       Quantities
  PACKAGE DATA




                                 Part Size                                                         Part                            Qty Parts per Container
                            Container Only                                             Dunnage (Tare)                       Container(s) per Layer on Pallet
                               Pallet Only                                             Container (Tare)                                      Later per Pallet
                     Unit Load As Shipped                                                 Pallet (Tare)                              Container(s) per Pallet
                        In to MM                 Lbs to Kg                   Container Gross (Inc Parts)                                      Stacking Rule
                                                                             Unit Load Gross (Inc Parts)
                                                                     Packaging Form
Date                                        Packaging Contact               Part Number                        Supplier Responsibilities Completed?
                                                                                                                          Packaging Design
Supplier Name                               Phone Number                    Print Revision Level                          Packaging that prevents
                                                                                                                          shipping and material
Supplier Code                               Fax Number                      Part Description                              handling defects
                                                                                                                          Electronic storage of
Supplier Production Facility                E-Mail Address                  HAZMAT?                                       submitted Packaging Data
                                                                                                                          Form


                                  Dunnage                    In Container Position                 Unit Load                As Shipped With Label Shown
   DIGITAL IMAGES




                    Description             Manufacturer         Material              Lead Time               RET/EXP             COMMENTS
                     Dunnage
 PACKAGING
 MATERIALS




                     Container Color
                     Container Type
                     Cover/Top Cap
                     Pallet
                     Stretch/Shrink Film
                     Banding
                     Other
                                        Specification Deviation Form
        Existing Production Deviation           PPAP Submission               Check Here to Request Print Changes

Part Name                                Part No:                                  Expiration Date


Drawing or Spec No.                      Revision                                  Revision Date                         Interim Action
                                                                                                                         Use As Is
Purchase order number                    Initiated By                              Maximum Units to be Deviated          Sort
                                                                                                                         Rework

                                                                                                                         Repair
    Requirement Stated on Drawing or         Actual Observed Results or             Deviation from Specification to be
             Specification                            Condition                                  Allowed




Interim Action




Interim Action Status        Effect on Cost, Quality and/or Delivery
Rework
          Choose One

Due Date



Corrective Action(s)
#           Action Item                                                Responsible Party      Due Date     Status




                             Cooper Internal Use Only- Engineering and Quality comments




Approval Signatures
                             Route To    Approve        Reject         Signature                           Date
Manufacturing Engineer
Manufacturing
Purchasing
Project Engineer
Quality

Engineering or Quality Final Disposition                                           Approve                 Reject
                                                                                                 GR&R Study - Multiple Operators                                                                                         X Da t a                                       Ra n g e Da t a                                                                  j    i ndex       Pa r t   Av e r a g eD4                 A2
                                                                                                                                                                                                                         Op 1 X AVG                                     Op 1 R AVG                  # DI V/ 0 !                                      1                                                    3. 267               1. 88
                                        For use with testing gage systems meant to evaluate features or processes whose output measured numerically, and for which two
                                                                                                                                                                                                                         Op 2 X AVG                                     Op 2 R AVG                  # DI V/ 0 !                                      2       3. 64997949                                  3. 267               1. 88
                                       to three operators are expected to conduct the evaluation.                                            Rev. 11/1/07 Dave Olson
                                                                                                                                                                                                                         Op 3 X AVG                                     Op 3 R Av g                 # DI V/ 0 !                                      3       2. 70018989                                  2. 574              1. 023
                                    Part Number:                                                        Supplier Name:                                                       Date                                        AVG o f X AVG                                  Av g o f R AVG                                                               4       2. 30582073                                  2. 282              0. 729
                                Drawing Number:                                                       Supplier Address:                                                                                                  R o f X AVG                                    R o f R AVG                                                                  5        2. 0802457                                  2. 114              0. 577
                                   Drawing Rev.:                                                                                                                    Supplier Contact                                                                                    ABS R Av g                                                                   6       1. 93158298                                  2. 004              0. 483
                                       Rev. Date:                                                                                                                                                                        Sp e c Ra n g e            0. 000              Pa r t s Te s t e d                       0                                  7       1. 82421546                                  1. 924              0. 419
                                Drawing Location:                                                 PCA Supplier Name:                                                  GR&R Contact                                       X- Ra n g e                                    # o f Op e r a t o r s                    0                                  8       1. 74214125                                  1. 864              0. 373
                                    Part Feature:                                                       PCA Address:                                                                                                     j =                     # N/ A                 # o f Tr i a l s                          0                                  9       1. 67710131                                  1. 816              0. 337
                                 Feature Symbol:                                                                                                                         PCA Contact                                     k=                          3. 65              R o f X AVGs                     0. 000                                     10       1. 62393374                                  1. 777              0. 308
                                Other Information                                                                                                                                                                        r=                          4. 56              UCL r                         # N/ A

                                                                                                                                                                                                                         d4=                     # N/ A                 UCL x                       # VAL UE!
           Calibration Date:                                                Gage Type:                                      Gage ID:                    Unit of Measure:                                                 a2=                     # N/ A                 L CL x                      # VAL UE!


                                Operator 1 Name                                                    Operator 2 Name                                          Operator 3 Name                                   Ba r - R   UCL x               L CL x          Ba r - X   Op 1 X                   Op 2 X               Op 3 X         Op 1 X- Ba r        Op 2 X- Ba r      Op 3 X- Ba r        Op 1 Ra n g e       Op 2 Ra n g e       Op 3 Ra n g e   UCL r
                                                                                                                                                                                                          1                      # VAL UE!      # VAL UE!                     Er r o r               Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
                     0             0                        0                                                                                                                                             2                      # VAL UE!      # VAL UE!                     Er r o r               Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
USL                                    LSL                                      Number of Trials:                                    Number of Operators:                                                 3                      # VAL UE!      # VAL UE!                     Er r o r               Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A



                                                                                                                                                                                                          4                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
                            Operator 1                                             Operator 2                                                                    Operator 3                               5                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
 Part #   1st Trial    2nd Trial       3rd Trial     Range       1st Trial    2nd Trial   3rd Trial                                      Range      1st Trial 2nd Trial 3rd Trial               Range     6                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
    1                                                  Error                                                                              Error                                                  Error    7                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
    2                                                  Error                                                                              Error                                                  Error    8                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
    3                                                  Error                                                                              Error                                                  Error    9                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
    4                                                  Error                                                                              Error                                                  Error   10                      # VAL UE!     # VAL UE!                         Er r o r            Er r o r             Er r o r                                                             Er r o r            Er r o r            Er r o r                # N/ A
    5                                                  Error                                                                              Error                                                  Error
    6                                                  Error                                                                              Error                                                  Error
    7                                                  Error                                                                              Error                                                  Error
    8                                                  Error                                                                              Error                                                  Error
    9                                                  Error                                                                              Error                                                  Error
   10                                                  Error                                                                              Error                                                  Error
* A minimum of six samples for each trial is required for these results to be valid

                                                 Gage R&R Summary                                                                             Gage R&R Disposition
                                             Measurement Unit Analysis
                                                Repeatability: EV= #VALUE!
                                              Reproducability: AV= #VALUE!
                                                                                                                                     Disposition                            #VALUE!
                                                              R&R= #VALUE!
                                               Part Variation: PV =  #N/A
                                               Total Variation: TV= #VALUE!                                                      GR&RTOL% < 10                      Pass - Gage System is Useable

                         % Process Variation (TV) / % Tolerance Variation (TOL)
                                                                                                                                                                     Gage System is useable but
                     % Equipment Variation (EVTV)  #VALUE!             %EVTOL   #VALUE!                                      10 ≤ GR&RTOL% ≤ 30
                                                                                                                                                                              marginal
                      % Appraiser Variation (AVTV) #VALUE!             %AVTOL   #VALUE!
                               %GR&R (GR&R TV)     #VALUE!          %GR&RTOL    #VALUE!
                           %Part Variation (PVTV)   #N/A                                                                         GR&RTOL% > 30                      Fail - Gage System is Unstable


                                          Part Operator Average                                                                      Repeatability Range (All Operators)
                                   Most part averages should be outside the control limits



                            1      2         3          4        5      6           7        8    9      10              1.000
                    1.000
                                                                                                                         0.900
                    0.900
                                                                                                                         0.800
                    0.800
                                                                                                                         0.700
Operator X Values




                    0.700
                                                                                                                         0.600
                                                                                                                 Bar R




                    0.600
                                                                                                                         0.500

                    0.500                                                                                                0.400

                    0.400                                                                                                0.300

                    0.300                                                                                                0.200

                                                                                                                         0.100
                    0.200

                                                                                                                         0.000
                    0.100
                                                                                                                                 1      2     3     4       5        6      7         8    9     10
                    0.000
                                                                                                                                              Sample Number
                                   UCLx          LCLx           Bar-X       Op1 X        Op2 X        Op3 X                      UCLr       Bar-R       Op1 Range         Op2 Range       Op3 Range
                                                  Process Capability Analysis - Ppk
                 Use when: (a) You are a new supplier to Cooper that has already been manufacturing the specified part, or (b) you are an existing
                                      supplier who has been found to have supplied a large number of nonconforming parts.


                    Are the Design Characteristics Safety Related, or Functional?
 Safety Related (Ppk ≥ 1.67)                                                                 Functional (Ppk ≥ 1.33)




    Part Number:                                               Supplier Name:                                                                         Date
Drawing Number:                                              Supplier Address:
    Drawing Rev.:                                                                                                                         Supplier Contact
        Rev. Date:
Drawing Location:                                         PCA Supplier Name:
     Part Feature:                                              PCA Address:
  Feature Symbol:
Other Information



         Limits                                               PCA Summary
   USL                                      Process Data                    Potential Capability

   LSL                                    LSL =         0.000               Ppku = Error in STDEV

                                         USL =          0.000               Ppkl = Error in STDEV
                                       Mean =         No Data               Ppk = Error in STDEV
    Test Data                         StDev =           0.000                   Pp = Error in STDEV

 Test No.       Test                                                       %Cr = Error in STDEV
     1                                                                      Max = 0.000
     2                                                                      Min = 0.000
     3

     4                                                  Spec          Frequency                                               Distribution
     5                                     1            0.000               0
     6                                     2            0.000               0
     7                                     3            0.000               0
     8                                     4            0.000               0
     9                                     5            0.000               0
    10                                     6            0.000               0
                                                                                        Frequency




    11                                     7            0.000               0
    12                                     8            0.000               0
    13                                     9            0.000               0
    14                                     10           0.000               0

    15
    16
    17
    18
                                                                                                    0.000




                                                                                                                      0.000




                                                                                                                                              0.000




                                                                                                                                                                        0.000
                                                                                                              0.000




                                                                                                                              0.000



                                                                                                                                      0.000




                                                                                                                                                        0.000



                                                                                                                                                                0.000




    19                                                                                                      Values

    20
    21
    22                                       Disposition                                Invalid PPK
    23                                         Ppk < 1.33                   Reject, Corrective Action Needed
    24                                         Ppk ≥ 1.33                                              Accept
    25


 Ppk Disp          1.33
                                                                                              Cpk for Subgroups
                     Use when: (a) new part, (b) part with revised specifications, (c) part in which the materials, processes, manufacturing location, or production equipment have significantly changed,
                                                                                    or (d) part in which the material suppliers have changed.
                                                                                                                                                                                                                                                                                                                        X   X-Bar   LCLx   UCLx   Range       R-Bar   UCLr


           Part Number:                                           Supplier Name:                                                                                                                                                        Date of Study
       Drawing Number:                                          Supplier Address:
          Drawing Rev.:                                                                                                                                                                                                            Supplier Contact
               Rev. Date:
       Drawing Location:                                     PCA Supplier Name:                                                                                                                                                       GR&R Contact
           Part Feature:                                           PCA Address:
        Feature Symbol:                                                                                                                                                                                                                    PCA Contact
       Other Information



                                                                                                                                                                                   PCA Summary                                                                                                                      1                                     0
           Subgroup Sizes                         Limits                                                                                      Process                Data                 Potential Capability                                                                                                      2                                     0
            30 Subgroups of Size 2             USL                                                                                           USL=                    0.000               Cp =    Error in STDEV                                                                                                     3                                     0
            25 Subgroups of Size 5             LSL                                                                                           LSL=                    0.000             CpkL =    Error in STDEV                                                                                                     4                                     0
            50 Subgroups of size 5                                                                                                          Mean=                     Error           CpkU =     Error in STDEV                                                                                                     5                                     0
                                                                                                                                          StDevE=                     Error             Cpk =         0.000                                                                                                         6                                     0
                                                                                                                                            UCLx=                                      %Cr =     Error in STDEV                                                                                                     7                                     0
                                                                                                                                            LCLx=                                       Max =                                                                                                                       8                                     0
                                                                                                                                            UCLR=                                       Min =                                                                                                                       9                                     0
                                                                                                                                                                                                                                                                                                                   10                                     0
Subgroup    Test 1    Test 2      Test 3      Test 4      Test 5         Average            Range                                                                                                                                                                                                                  11                                     0
   1                                                                                            0.000                                     Spec             Frequency                                                                    Histogram                                                                  12                                     0
   2                                                                                            0.000                        1            #VALUE!                                                                                                                                                                  13                                     0
   3                                                                                            0.000                        2            #VALUE!                                                                                                                                                                  14                                     0




                                                                                                                                                                                            Frequency
   4                                                                                            0.000                        3            #VALUE!                                                                                                                                                                  15                                     0
   5                                                                                            0.000                        4            #VALUE!                                                                                                                                                                  16                                     0
   6                                                                                            0.000                        5            #VALUE!                                                                                                                                                                  17                                     0
   7                                                                                            0.000                        6            #VALUE!                                                                                                                                                                  18                                     0
   8                                                                                            0.000                        7            #VALUE!                                                                                                                                                                  19                                     0




                                                                                                                                                                                                         0.000


                                                                                                                                                                                                                      0.000


                                                                                                                                                                                                                                   0.000


                                                                                                                                                                                                                                             0.000


                                                                                                                                                                                                                                                          0.000


                                                                                                                                                                                                                                                                         0.000


                                                                                                                                                                                                                                                                                      0.000


                                                                                                                                                                                                                                                                                              0.000


                                                                                                                                                                                                                                                                                                           0.000
   9                                                                                            0.000                        8            #VALUE!                                                                                                                                                                  20                                     0
  10                                                                                            0.000                        9            #VALUE!                                                                                          Test Values                                                             21                                     0
  11                                                                                            0.000                                                                  Averages Chart                                                                                                                              22                                     0
  12                                                                                            0.000                        1
                                                                                                                                                                                                                                                                                                                   23                                     0
  13                                                                                            0.000                       0.9
                                                                                                                                                                                                                                                                                                                   24                                     0
  14                                                                                            0.000                                                                                                                                                                                                              25                                     0
  15                                                                                            0.000                                                                                                                                                                                                              26
                                                                                                                            0.8



  16                                                                                            0.000                       0.7                                                                                                                                                                                    27
  17                                                                                            0.000                                                                                                                                                                                                              28
                                                                                                             Sample Value




                                                                                                                            0.6
  18                                                                                            0.000                                                                                                                                                                                                              29
  19                                                                                            0.000                       0.5                                                                                                                                                                                    30
  20                                                                                            0.000                                                                                                                                                                                                              31
                                                                                                                            0.4
  21                                                                                            0.000                                                                                                                                                                                                              32
  22                                                                                            0.000                       0.3                                                                                                                                                                                    33
  23                                                                                            0.000                       0.2
                                                                                                                                                                                                                                                                                                                   34
  24                                                                                            0.000                                                                                                                                                                                                              35
  25                                                                                            0.000                       0.1
                                                                                                                                                                                                                                                                                                                   36
  26                                                                                                                         0                                                                                                                                                                                     37
                                                                                                                                  1



                                                                                                                                          5



                                                                                                                                                  9



                                                                                                                                                           13



                                                                                                                                                                        17



                                                                                                                                                                                   21



                                                                                                                                                                                               25




                                                                                                                                                                                                                                                 37



                                                                                                                                                                                                                                                                   41



                                                                                                                                                                                                                                                                                      45



                                                                                                                                                                                                                                                                                                      49
                                                                                                                                                                                                                 29



                                                                                                                                                                                                                                   33




  27                                                                                                                                                                                                                                                                                                               38
                                                                                                                                                                             Sample Number
  28                                                                                                                                                                                                                                                                                                               39
                                                                                                                                              X                        X-Bar                                 LCLx                                                 UCLx
  29                                                                                                                                                                                                                                                                                                               40
  30                                                                                                                                                                                                                                                                                                               41
  31                                                                                                                                                                          Control Chart                                                                                                                        42
  32                                                                                                                                                                                                                                                                                                               43
                                                                                                                                  1
  33                                                                                                                                                                                                                                                                                                               44
  34                                                                                                                         0.9                                                                                                                                                                                   45
  35                                                                                                                                                                                                                                                                                                               46
                                                                                                                             0.8
  36                                                                                                                                                                                                                                                                                                               47
  37                                                                                                                         0.7                                                                                                                                                                                   48
  38                                                                                                                                                                                                                                                                                                               49
                                                                                                                             0.6
                                                                                                             Range




  39                                                                                                                                                                                                                                                                                                               50
  40                                                                                                                         0.5

  41
                                                                                                                             0.4
  42
                                                                                                                             0.3
  43
  44                                                                                                                         0.2
  45
                                                                                                                             0.1
  46
  47                                                                                                                              0
                                                                                                                                      1




                                                                                                                                                  7
                                                                                                                                          3

                                                                                                                                              5



                                                                                                                                                      9



                                                                                                                                                                13

                                                                                                                                                                      15




                                                                                                                                                                                       21




                                                                                                                                                                                                         27

                                                                                                                                                                                                                  29



                                                                                                                                                                                                                                    33

                                                                                                                                                                                                                                            35




                                                                                                                                                                                                                                                                     41




                                                                                                                                                                                                                                                                                              47

                                                                                                                                                                                                                                                                                                      49
                                                                                                                                                          11




                                                                                                                                                                             17

                                                                                                                                                                                  19



                                                                                                                                                                                            23

                                                                                                                                                                                                    25




                                                                                                                                                                                                                              31




                                                                                                                                                                                                                                                     37

                                                                                                                                                                                                                                                           39



                                                                                                                                                                                                                                                                                 43

                                                                                                                                                                                                                                                                                        45




  48
                                                                                                                                                                              Sample Number
  49                                                                                                                                                                 Range                                R-Bar                                                   UCLr

  50
                                                                                                                   Cpk for Moving Range
                            Use when: (a) new part, (b) part with revised specifications, (c) part in which the materials, processes, manufacturing location, or production equipment
                            have significantly changed, or (d) part in which the material suppliers have changed AND testing is too expensive to be conducted by subgroups.




                       Part Number:                                                    Supplier Name:                                                                                                                                           Date
                   Drawing Number:                                                   Supplier Address:
                      Drawing Rev.:                                                                                                                                                                                               Supplier Contact
                          Rev. Date:
                  Drawing Location:                                           PCA Supplier Name:                                                                                                                                        GR&R Contact
                       Part Feature:                                                PCA Address:
                    Feature Symbol:                                                                                                                                                                                                     PCA Contact
                  Other Information




USL
                                                                                                           PCA Summary                                                                                 Distribution
LSL
                                                                                 Process Data                              Potential Capability

Subgroup Test Value       Range                                             LSL=                   0                       Cp=
      1                                                                     USL=                   0                  CpkL=
      2                          0.00                                      Mean=                                     CpkU=
      3                          0.00                                      StDev                   0                   Cpk=                  0




                                                                                                                                                                Frequency
      4                          0.00                                      UCLX=                                      %Cr=
      5                          0.00                                      LCLX=                                       Max=               0.0000
      6                          0.00                                      UCLR=                   0                   Min=               0.0000
      7                          0.00

      8                          0.00                                                          Spec              Frequency
      9                          0.00                                        1                         0.0000         0
      10                         0.00                                        2                         0.0000         0
      11                         0.00                                        3                         0.0000         0
      12                         0.00                                        4                         0.0000         0
      13                         0.00                                        5                         0.0000         0




                                                                                                                                                                                         0.0000




                                                                                                                                                                                                                  0.0000



                                                                                                                                                                                                                               0.0000




                                                                                                                                                                                                                                                       0.0000



                                                                                                                                                                                                                                                                0.0000
                                                                                                                                                                                0.0000




                                                                                                                                                                                                       0.0000




                                                                                                                                                                                                                                             0.0000
      14                         0.00                                        6                         0.0000         0
      15                         0.00                                        7                         0.0000         0
                                                                                                                                                                                                                Test Values
      16                         0.00                                        8                         0.0000         0

      17                         0.00
                                                                                                                                          Averages
      18                         0.00                       1
      19                         0.00                       1
      20                         0.00
                                                            1
      21                         0.00
      22                         0.00                       1

      23                         0.00                       1
                                           Test Value




      24                         0.00
                                                            1
      25                         0.00
                                                            0
      26                         0.00
      27                         0.00                       0

      28                         0.00                       0
      29                         0.00
                                                            0
      30                         0.00
                                                            0
      31                         0.00
                                                                    1            5             9           13          17         21          25           29                 33                  37              41                    45             49
      32                         0.00
                                                                    Sample Number
                                                                                                                                  X                X-Bar                    Upper Control Limit                            Lower Control Limit
      33                         0.00
      34                         0.00
      35                         0.00
                                                                                                                                 Range Chart
                                                        1
      36                         0.00
      37                         0.00                   1
      38                         0.00                   1
      39                         0.00
                                                        1
      40                         0.00
      41                         0.00                   1
                                          Range




      42                         0.00                   1
      43                         0.00
                                                        0
      44                         0.00
      45                         0.00                   0
      46                         0.00                   0
      47                         0.00
                                                        0
      48                         0.00
      49                         0.00                   0
                                                                1            5             9              13          17         21          25            29                  33                 37               41                    45                49
      50                         0.00
                                                                Sample
Average                          0.00                                                                          Range UCL               Range Average                         Moving Range Average


           UCLX           LCLX          Mean            UCLR              XmR     Range Average
       1                                                                0 #DIV/0!            0.00
       2                                                                0    0.00            0.00
       3                                                                0    0.00            0.00
       4                                                                0    0.00            0.00
       5                                                                0    0.00            0.00
       6                                                                0    0.00            0.00
       7                                                                0    0.00            0.00
       8                                                                0    0.00            0.00
       9                                                                0    0.00            0.00
      10                                                                0    0.00            0.00
      11                                                                0    0.00            0.00
      12                                                                0    0.00            0.00
      13                                                                0    0.00            0.00
      14                                                                0    0.00            0.00
      15                                                                0    0.00            0.00
      16                                                                0    0.00            0.00
      17                                                                0    0.00            0.00
      18                                                                0    0.00            0.00
      19                                                                0    0.00            0.00
      20                                                                0    0.00            0.00
      21                                                                0    0.00            0.00
      22                                                                0    0.00            0.00
      23                                                                0    0.00            0.00
      24                                                                0    0.00            0.00
      25                                                                0    0.00            0.00
      26                                                                0    0.00            0.00
      27                                                                0    0.00            0.00
      28                                                                0    0.00            0.00
      29                                                                0    0.00            0.00
      30                                                                0    0.00            0.00
      31                                                                0    0.00            0.00
      32                                                                0    0.00            0.00
      33                                                                0    0.00            0.00
      34                                                                0    0.00            0.00
      35                                                                0    0.00            0.00
      36                                                                0    0.00            0.00
      37                                                                0    0.00            0.00
      38                                                                0    0.00            0.00
      39                                                                0    0.00            0.00
      40                                                                0    0.00            0.00
      41                                                                0    0.00            0.00
      42                                                                0    0.00            0.00
      43                                                                0    0.00            0.00
      44                                                                0    0.00            0.00
      45                                                                0    0.00            0.00
      46                                                                0    0.00            0.00
      47                                                                0    0.00            0.00
      48                                                                0    0.00            0.00
      49                                                                0    0.00            0.00
      50                                                                0    0.00            0.00

				
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