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What is APQP?
Advanced Product Quality
Planning Cycle
APQP Background
Automotive industry challenges:
Solution:
Ford, GM, Chrysler APQP Task Force jointly developed in
the late 80s to standardize their respective supplier quality
systems.
Continuous Improvement:
Many industries outside the Automotive industry have
embraced the AIAG APQP process to achieve similar
benefits
INPUTS:
Assure that
customer needs
and expectations
are clearly
understood.
Design Goals
Reliability & Quality
goals
CONC targets
Preliminary Bill of
Materials
Preliminary Process
Flow Chart
Preliminary list of
Special Product and
Process
Characteristics
Product Assurance
Plan
Management Support
* The inputs and outputs applicable to the process may vary according to the
product process and customer needs and expectations.
OUTPUTS:
Design Failure Mode and Effects
Analysis (DFMEA)
Design For Manufacturability and
Assembly
Design Verification
Design Reviews
Prototype Build Control plan
Engineering Drawings (Including
Math Data)
Engineering Specifications
Material Specifications
Drawing and Specification
Changes
OUTPUTS:
New Equipment, Tooling and
Facilities Requirements
Special Product and Process
Characteristics
Gages/Testing Equipment
Requirements
Team Feasibility
Commitment
Management Support
Develop a
manufacturing
system and its
related control
plans to achieve
quality products.
OUTPUTS:
Packaging Standards
Product/Process Quality
System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and
Effects Analysis (PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems
Analysis Plan
Preliminary Process
Capability Study Plan
Packaging Specifications
Management Support
Validate manufacturing
process through
production trial run.
Validate that the control
plan and process flow
chart are effective and
that the product meets
customer expectation.
Packaging Standards
Product/Process Quality
System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and
Effects Analysis (PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems
Analysis Plan
Preliminary Process
Capability Study Plan
Packaging Specifications
Management Support
OUTPUTS:
Measurement Systems
Evaluation
Significant Production Run
Preliminary Process
Capability Study
Production Part Approval
Production Validation
Testing
Packaging Evaluation
Production Control Plan
Quality Planning Sign-Off formal
Management Support
Evaluate outputs,
effectiveness of
the product
quality planning
efforts.
OUTPUTS:
Reduced Variation
Improved Customer
Satisfaction
Improved Delivery and
Service
Effective use of best
practice, lessons learned
Maximum ROI
Minimum Waste
Minimum CONC
10
Low Volume
APQP plans may be specific to part families with activities
focused on the parent part
More limited validation would be done on child parts
Family part differences should be understood and higher risk
differences incorporated into APQP plans
11
APQP Summary:
What we do:
Design Quality
DFMEA / PFMEA /
DFM/A
Manufacturing Quality
Control Plans
Process Flows
Measurement System
Analysis
Capability Analysis
Process Validation
Run at rate
Supplier Qualification &
Quality Requirements
Product Qualification
1st Article Inspection
PPAP
Tooling & Gauges
Testing
How we do it:
APQP
What we get:
UP
FRONT
DETAILED
QUALITY
PLANNING
Leadership
Engagement is Critical
1
2014 Eaton. All Rights Reserved.
12
APQP Benefits:
Manufacturing process functions that are clearly planned,
validated, documented and communicated that result in:
CONC
Redesign
Re-qualifications
Escape Investigations
Development
Production
Time
13
14
16
16
What is PPAP?
Production Part Approval Process
Standard used to formally reduce risks prior to
product or service release, in a team oriented
manner using well established tools and
techniques
Initially developed by AIAG (Auto Industry Action
Group) in 1993 with input from the Big 3 - Ford,
Chrysler, and GM
AIAGs 4th edition effective June 1, 2006 is the
most recent version
PPAP has now spread to many different industries
beyond automotive
17
Production Run
PPAP data must be submitted from a
production run using:
18
Purpose of PPAP
Provide evidence that all customer engineering
design record and specification requirements
are properly understood by the organization
To demonstrate that the manufacturing
process has the potential to produce product
that consistently meets all requirements during
an actual production run at the quoted
production rate
19
20
20
Correction of discrepancy
Change to optional construction or material
Sub-supplier or material source change
Change in part processing
Parts produced at a new or additional location
21
22
Level 2
Level 3
Level 4
Level 5
23
24
25
PPAP Status
Approved
The part meets all Eaton requirements
Supplier is authorized to ship production quantities of
the part
Interim Approval
Permits shipment of part on a limited time or piece
quantity basis
Rejected
The part does not meet Eaton requirements, based on
the production lot from which it was taken and/or
accompanying documentation
26
27
28
Component drawings
Assembly drawings
Bill of Materials
Referenced engineering specifications
Material specifications
Performance or test specifications
29
30
31
Materials selection
Tolerance stack-up
Software
Interfaces
DVP&R (life cycle tests)
PROLaunch element
Initial DFMEA in Phase 2
Complete DFMEA in Phase 3
32
33
34
Potential Failure
Effects
Low Flow at High
Speeds & High Flows
Reduced Overall
Relief Valve
Efficiency due to
Open
Internal Leakage
Reduced Overall
Housing
Efficiency due to
Fracture
Internal Leakage
Class
S
E
V
Potential
Causes
O
C
C
Impeller Fracture
Housing Fracture
due to Vibration
Actions Recommended
Action
Owner
Current
Controls
Prevent
Current Controls
Detect
Impeller stress analysis,
thermal limits, vibration
analysis
Relief valve force margin,
relief valve clearances,
sharp edges
Analyze housing vibration
modes in conjunction with
vibration requirements
Target
Date
Actions N S
e E
Taken
D
E
T
R
P
N
96
120
72
w V
N O
e C
w C
N D
e E
w T
N R
e P
w N
Stackups
complete
32
Jan Doe
Analysis
complete
32
Thermal
Joe Smith 12-Sep-14 analysis
complete
36
11-Aug-14
35
Create PFMEA
Customer CTQs After
identified
Suppliers Selected
Gage Plan CreatedAfter
36
37
ORGANIZATION
CITY
STATE
Issue Date
ECL
Part Name
NAME
Part Number
ECL
NUMBER
Legend:
STEP
Operation
Transportation
Operation or Event
Inspection
Delay
Storage
Description of
Evaluation
Operation or Event
38
Engineers
Operators
Supervisors
Maintenance
Supply Chain
Engineering specifications
Lead time requirements
Target manufacturing costs
Operator experience
Observation
Brainstorming
39
Receiving
Storage/ material handling
Manufacturing
Offline inspections and checks
Assembly
Testing
Shipping
40
41
Process Responsibility
Model Year(s)/Program(s)
APPLICATION
ORGANIZATION
Key Date
Requirements
Potential
Effect(s)
of Failure
Potential
Causes(s)
of Failure
Current
Process
Controls
Current
Process
Controls
Prevention
Detection
RPN
Potential
Failure
Mode
Detection
Process Step
/ Function
Occurrence
Core Team:
Objective or Purpose
Identifies potential failure modes,
causes, and effects. Inputs come from
the process flow diagram.
Identifies key inputs which affect quality,
reliability and safety of a product or
process.
Item:
Severity
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
Classification
When to Use It
New product launches
After completion of the process flow
diagram.
Prior to tooling for production
IMPORTANT!
The PFMEA should be completed
using a cross-functional team!
42
FMEA Origins
Ap
F
2014 Eaton. All Rights Reserved.
43
PFMEA - Step 1
Current Controls
Customer unable to
install product, due
to missing hardware.
Prevent
What are the existing
process controls to
prevent the cause of
failure or failure mode
from occurring or
reduce the rate of
occurrence?
Should include an
SOP number.
Detect
What are the existing
process controls to
detect the cause of
failure or failure mode
and lead to corrective
action(s)?
Should include an
SOP number.
D
E
T
How well can you detect the cause of
failure mode? See DET table.
O
C
C
S
E
Potential Failure
Failure
Modes
V
Effects
Potential Causes
WhatFor
is theeach
impact Process Input,
What causes the input
on
the output
to go wrong?
determine
the ways in
variables (customer
which the input can
go
requirements)
What
could cause the
or internal
failure, in terms of
wrong.
requirements?
something that can be
corrected or controlled?
What are the effects
of the failure on the
function as perceived
by internal and
external customers?
How severe is the effect to the customer?
See SEV table.
Process Step
What is the process
step or input being
evaluated?
Potential Failure
Mode
In what way(s) could
the step or input fail to
meet the specificed
requirements?
Consider:
(A) No Function
(B)
Partial/Over/Degraded
Function
(C) Intermittent
Function
(D) Unintended
Function.
C
L
A
S
S
Work Instructions,
Pack Positive
Visual Inspection;
Scale to weigh kits
Bagger error
Work Instructions
Visual Inspection
TIP
There should be at least one failure mode for each input.
2014 Eaton. All Rights Reserved.
44
List all credible failure modes or ways the process/operation can fail in the
PFMEA document before addressing failure effects and failure causes
In each instance, the assumption is made that the failure could occur, but
will not necessarily occur
The failure mode:
is the manner in which the process could potentially fail to meet the process
requirements and/or design intent.
Is a description of nonconformance
Assumes incoming parts are correct
Considers subsequent operations
Typical failure modes could be, but are not limited to:
Bent
Open circuited
Dirty
Binding
Cracked
Improper setup
Burred
Deformed
Tool worn
Handling Damage
45
Bend
Test
Insert
Missing Component
X Orientation
Wrong Component
Z Orientation
Multiple Components
X Location
Y Location
Z Location
Radial Orientation
Dirt Contamination
Damage
Upside down
Backwards
Y Orientation
Radial Orientation
Dirt Contamination
Damage
Flattened
Cracked
Folded
Broken fold
Scratch
Dents
Chips
Deformed
No bend
No test
No Insertion
Over Insertion
Remove / Unload
Index
Measure
Miscategorization
No remove
Missed op
Damage
Contamination
No measure
Inaccurate Gaging
46
Dip
Package
No Stake
Missed Operation
Incorrect Qty
Under Stake
Over Stake
Partial Dip
Incorrect Label
Incorrect Box
Mixed Parts
Damage
Feed-Out
Wrong Wire
No Feed
Feed Too Short
Feed Too Long
Wind
Too Few Coils
Too Many Coils
Free Length Short
Free Length Long
Cut-Off
No Cut-Off
Initialize
Synchronize
Fail to Recognize
Fail to Clear Registers Station
Write Incorrect Value
to Register During
Clearing
No Synchronize
Press
High force
Low force
Tooling alignment
Too Fast Speed
Too slow speed
Short stroke
Over stroke
Load
Wrong part
Mix part
Dirty part
Wrong lane
Wrong orientation
Damage
Setup
Incorrect Setup
Pump-Up
Does not Pump-Up
Incomplete Setup
No Setup
Fill / Oil
Wrong fluid
Too much fluid
Too little fluid
Torque
Damaged component
No torque
Over torque
47
Mark
Incomplete
Illegible
Wrong Mark
Grease
Mold
Wrong Grease
no grease
X-Y Orientation
Density variation
Dimension variation
Sink
Z Orientation
Flowlines
Damage
Too much
Too little
Contamination
Incorrect number of
greasing points
Shorts
Warp
Molded contamination
Weldlines
color variation
brittleness
scratches
drag marks
gate stubs
burns
flash
mixed parts
part count incorrect
bubbles
sirface contamination
voids
splay
damaged part
wrong part
48
PFMEA - Step 2
Potential Failure Effects
For each Failure Mode,
determine what effect
the specific failure
could have on the
process output.
TIPS
There should be at least one failure effect for each failure mode.
Effects should be specific, clear, and leave no doubt to the uninformed reviewer.
2014 Eaton. All Rights Reserved.
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50
PFMEA Step 3
Class
Identify special product
or process
characteristics
51
PFMEA - Step 4
Potential Causes
For each Failure Mode,
determine the possible
cause of the failure.
TIP
There should be at least one potential cause for each failure mode.
2014 Eaton. All Rights Reserved.
52
53
PFMEA - Step 5
Current Controls
For each potential cause,
list the current method
used for preventing
and/or detecting failure.
TIPS
This step in the FMEA begins to identify initial shortcomings or gaps in the current control plan.
If no current control exists, list as none. There may not be both preventive and detection controls.
2014 Eaton. All Rights Reserved.
54
PFMEA - Step 6
Assign Detection
(How easily can the
cause or failure
mode be detected?)
Assign Severity
(How serious is the
effect if it fails?)
Assign
Occurrence
(How likely is
the cause to
occur?)
55
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Rank
10
9
8
6
5
Effect
Failure to Meet Potential failure mode affects safe Product operation and/or involves
noncompliance with government regulation without warning
Safety and/or
Regulatory
Potential failure mode affects safe Product operation and/or involves
Requirements
noncompliance with government regulation with warning
Loss or
Degradation of
Primary
Function
No Effect
Significant
Disruption
Failure to Meet
Safety and/or
Regulatory
Requirements
Major Disruption
Effect
Criteria:
Severity of Effect on Process
(Manufacturing / Assembly Effect)
4
3
Criteria:
Severity of Effect on Product
(Customer Effect)
No discernible effect
High Disruption
Moderate
Disruption
No discernible effect
57
Rank
Likelihood of
Failure
10
Very High
9
8
High
Moderate
4
3
Low
2
1
6
5
Criteria:
Occurrence of Cause - DFMEA
(Incidents per Item / Products)
Very Low
2 per Thousand
1 in 500
0.5 per Thousand
1 in 2,000
0.1 per Thousand
1 in 10,000
0.01 per Thousand
1 in 100,000
=< 0.001 per Thousand
1 in 1,000,000
Failure is eliminated through preventive control
2014 Eaton. All Rights Reserved.
58
Likelihood
of
Detection
10
Almost
Impossible
No Detection Opportunity
Very Remote
Failure Mode and/or Error (Cause) is not easily detected (eg random audits)
Remote
Failure Mode detection post processing by operator through visual tactile audible
means
Very Low
Failure Mode detection in-station by operator through visual tactile audible means or
post processing through use of attribute gauging (go/no go, manual torque check /
clicker wrench etc.)
Low
Failure Mode detection post processing by operator through variable gauging or instation by operator through the use of attribute gauging (go/no go, manual torque
check / clicker wrench etc.)
Moderate
Failure Mode or Error (Cause) detection in-station by operator through the use of
variable gauging or by automated controls in-station that will detect discrepant part
and notify operator (light buzzer etc.). Gauging performed on set-up and first piece
check (for set-up causes only)
Moderately
High
Failure Mode detection post processing by automated controls that will detect
discrepant part and lock part to prevent further processing.
High
Failure Mode detection in-station by automated controls that will detect discrepant
part and automatically lock part in station to prevent further processing.
Very High
Error (Cause) detection in-station by automated controls that will detect error and
prevent discrepant part from being made.
Almost
Certain
Error (Cause) prevention as a result of fixture design, machine design or part design.
discrepant parts cannot be made because item has been error proofed by
process/product design.
Inspection Types
A - Error
BProofed Gauged
Criteria:
Likelihood of Detection by Design Control
CManual
59
PFMEA - Step 7
Process Step
Assemble Hardware Kit
Current Controls
Potential Failure
Mode
Potential Failure
Effects
Customer unable to
install product
Customer unable to
install product, due
to missing hardware.
Bagger error
TIPS
S
E
V
C
L
A
S
S
Potential Causes
O
C
C
D
E
T
R
P
N
Prevent
Detect
Work Instructions,
Pack Positive
Visual Inspection;
Scale to weigh kits
192
Work Instructions
Visual Inspection
128
60
61
FMEA Step 8
Current Controls
Prevent
Detect
Work Instructions,
Pack Positive
Visual Inspection;
Scale to weigh kits
Work Instructions
Visual Inspection
D
E
T
R
P
N
192
128
Actions
Recommended
Implement scale to
weigh hardware kits
Repair/replace worn
bagger
S
E
V
O
C
C
D
E
T
R
P
N
Responsible
Actions Taken
Kolumban
120
Zindler
64
62
Prevent
Detect
Work Instructions,
Pack Positive
Visual Inspection;
Scale to weigh kits
Resp
(responsibility)
Work Instructions
Visual Inspection
Assign a specific person
who will be responsible
for recommended actions.
D
E
T
R
P
N
192
128
Actions
Recommended
S
E
V
O
C
C
D
E
T
R
P
N
Responsible
Actions Taken
Kolumban
120
Zindler
64
Implement scale to
weigh hardware kits
Repair/replace worn
bagger
Actions Taken
As actions are identified
and completed, document
in the Actions Taken
column.
For each Process Input, determine the ways in which the Process
Step can go wrong (these are Failure Modes)
2. For each Failure Mode associated with the inputs, determine
Effects on the outputs
3. Mark special characteristics (product and process)
4. Identify potential Causes of each Failure Mode
5. List the Current Controls for each Cause
6. Assign Severity, Occurrence and Detection ratings after creating
a ratings key appropriate for your project
7. Calculate RPN
8. Determine Recommended Actions to reduce high risks
9. Take appropriate Actions and Document
10. Recalculate RPNs
11. Revisit steps 7 and 8 to continually reduce risks
64
Process
step/Input
Potential
Potential
Failure Mode Failure Effects
S
E
V
C
l
a
s
s
7
No grease in
bearing sleeve
Op 35.
Test and
grease
No grease in
bearing
(Product Z
only)
Sleeve/bearing
wears out warranty claim
Customer will
not be able to
install
Damage to
mounting
holes
cosmetic issue
and potential
effect on bolt
torque
DATE (Orig)
Visual inspection
R
P
N
Actions
Recommended
Add message to
prompt the
operator that the
grease is off. Add
sensor to grease
280 valve to sense that
it is firing.
3/1/2002
Add sensors to
confirm correct
voume block is
used
Actions Taken
S
E
V
O
C
C
D
E
T
R
P
N
BPB. October
2004
Completed
120
96
Modified equipment
and changed
program to look at
sensors
64
64
64
Impropoer grease
volume block used
Visual inspection
112
Grease not
pumping or barrel
empty
Visual inspection
TP12
Impropoer grease
volume block used
Visual inspection
112
Wrong set-up
100% inspection of
housing in tester
48
Part mislocated in
tester fixture
120
Add sensors to
confirm correct
voume block is
used
Modified equipment
and changed
program to look at
sensors
0
Modify program to
PT. December
prompt operator to
2010 Completed
check orientation
Change design of
fixture and
locators
(REV) 3/1/2011
Resp.
Premature
bearing/sleeve
failure - warranty
claim
7
Wrong bearing
housing
Potential
Causes(s)
of Failure
RESPONSIBLE
TEAM LEADER: Jane Doe
PT. February
2011 Completed
Modified program
105
Installed March
2011
70
65
66
67
Objective? - Planning
Needed gaging, testing, error
proofing
Sampling and frequencies
How to react when something
fails a test or inspection
When to Use It
Implementing a new process
Implementing a process
change
68
Control Plan
Tool Interaction
Department/Group Project
High Level Process Map
Project Idea
6 Sigma Project
High Level Process Map
Process Step
Fill Out Master
Form
with Initial
Information
Get WO Assigned
Begin/Work
Project
Follow DMAIC or
DFSS process
6 Sigma Assigns
Project Number
Other Required
Signatures:
Segment CEO
Champion
Process Owner
BB or GB
Monitor Progress
through Power
Steering and
Monthly
Financial
Reviews
Finance Approval
and Signature
No
Finance Approval
and Signature
No
Enter Remaining
Information on
Master Form
Do you
have BB/GB to
Assist/Work the
project?
Monitor Progress
through BiWeekly Updates
and Monthly
Reviews
6 Sigma
Project
Does the
Project Involve
>2 Groups in
Eng?
Yes
Department
or Group
Project
Identify
Customer
Identify Invoice
Enter Remaining
Information on
Master Form
Does the
Project Involve
>3 Depts.
outside Eng?
Delay internal
mail
Potential
Failure Effects
AR balance does
not go down
Wire
Transfer
reference
line
Checks
Incorrect
invoice
supplied
Finance Approval
and Signature
Other Required
Signatures:
Champion: Dir T&E
Process Owner
Project Owner
Dept BB or MBB
No
Yes
Yes
Process Steps
Follow DMAIC or
DFSS process
Checks
Potential
Failure Mode
S
E Potential Causes
V
Inadequate
staffing in mail
7 room
Customer or bank
did not include
name and/or
10 account info on
wire transfer
Final Project
Review
No
No
Close
Project
Begin/Work
Project
Is Hard
Savings > $???
Does the
Project Involve
Only Your
Group?
Other Required
Signatures:
Champion: Dir T&E
Process Owner
Project Owner
Dept BB or MBB
Receive
Payment
Get DLN
Assigned
Complete Project
(Has to be fully
Documented)
Finance Approval
and Signature
Complete all
Documentation
including a
(1) Page Closeout Sheet
Group Assigns
Project Number
Yes
Yes
Final Project
Review
Prefer to work
this project
within your
area?
Yes
Complete Project
(Has to be fully
Documented
Other Required
Signatures:
Champion:
Process Owner
Project Owner
Dept GB/BB/MBB
Key
Process
Input
No
Close
Project
Complete all
Documentation
including a
(1) Page Closeout Sheet
Identify Invoice
Checks
Invoice shows
outstanding (AR
balance does go
down)
Customer error
Customer error
O
C
C
Current Controls
D
E
T
R
P
N
None
7
10 490
E
O
C
Actions
Recommended
Investigate mail room
staffing and associated
processes
250
d
ze
i
it p
or Ste
i
Pr ss
sk ce
Ri ro
P
10 250
250
Process FMEA
Process Flowchart
Control Plan
Pr
oc
es
69
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
70
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
Administrative Section
Identifies part number and description,
supplier, required approval signatures,
and dates.
71
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
3 Distinct Phases
1. Prototype a description of the dimensional measurements and material
and performance tests that will occur during Prototype build.
2. Pre-Launch a description of the dimensional measurements and material
and performance tests that will occur after Prototype and before full
Production.
3. Production a comprehensive documentation of product/process
characteristics, process controls, tests, and measurement systems that will
occur during mass production
2014 Eaton. All Rights Reserved.
72
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
73
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
74
75
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
76
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
77
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
78
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
Organization Code
ORGANIZATION
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
79
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
80
CONTROL PLAN
Pre-Launch
Production
Key Contact/Phone
FILE.XLS
Date (Orig.)
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Organization/Plant Approval/Date
ECL
Part Name/Description
NAME
Organization/Plant
ORGANIZATION
Organization Code
CODE
MACHINE,
CHARACTERISTICS
METHODS
PART/ PROCESS NAME/
SPECIAL
DEVICE
SAMPLE
PROCESS
OPERATION
CHAR. PRODUCT/PROCESSEVALUATION/
JIG, TOOLS
NO. PRODUCT PROCESS CLASS
SPECIFICATION/ MEASUREMENT
NUMBER DESCRIPTION
SIZE
FREQ.
FOR MFG.
TOLERANCE
TECHNIQUE
CONTROL
METHOD
REACTION
PLAN
81
CONTROL PLAN
Prototype
Pre-Launch
Machine,
Process Name
Device,
/ Operation
Jig, Tools,
Description
for MFG.
Soldering
Connections
Wave
solder
machine
Production
Key Contact/Phone
T. Smith / 313-555-5555
Core Team
Erin Hope, Alan Burt, Ken Light
Supplier/Plant Approval/Date
Date:(Org.)
Date (Rev.)
11/29/2009
2/20/2010
Customer Engineering Approval/Date (If Req'd.)
Characteristics
No.
Product
Methods
Process
Wave
solder
height
Special
Char.
Class
Product/Process Evaluation /
Specification/ Measurement
Tolerance
Technique
Standard #302B
Sensor
continuity
check
Test sampling
lab
environment
Sample
Size
100%
1 pc
Freq.
Control
Method
Automated
inspection
(error
Continuous proofing)
4 hours
Reaction
Plan
Adjust and
retest
Segregate
x-MR chart and retest
82
Use process flow diagram and PFMEA to build the control plan; keep them
aligned
Controls should be effective. Keep it simple.
Ensure that the control plan is in your document control system
Good control plans address:
The control method should be based on an effective analysis of the
process
Control plans should reference other documentation
83
84
When to Use It
On systems measuring critical inputs
and outputs prior to collecting data for
analysis.
For any new or modified process in
order to ensure the quality of the data.
Who Should be Involved
Everyone that measures and makes
decisions about these measurements
should be involved in the MSA.
85
86
Observed Variation
Resolution
Precision
(Variability)
Repeatability
Reproducibility
Measurement
System
Variation
Linearity
Accuracy
Observed
Variation
(Central
Location)
Bias
Stability
Process
Variation
87
Resolution
Error in Resolution
Possible Cause
88
Possible Cause
Equipment Variation
89
Possible Cause
Appraiser Variation
90
91
Gage Name
Appraiser A
NUMBER
Gage Name
Appraiser A
Gage Number
Appraiser B
Characteristic
Gage Type
Appraiser C
Characteristic Classification
Trials
NUMBER
Part Name
Gage Number
Appraiser B
Part Name
NAME
NAME
Characteristic
Specification
Gage Type
Appraiser C
Lower Upper
Characteristic Classification
Trials
Parts
APPRAISER/
Appraisers
Date Performed
PART
1. A
2.
10
Appraisers
AVERAGE
Parts
Date Performed
% Tolerance (Tol)
Trials
K1
0.8862
0.5908
3.
4.
AVE
5.
6. B
7.
8.
9.
AVE
b=
10.
b=
xa=
ra=
Automatically calculatesx
r
%GRR, %PV, ndc
R x K1
% EV
1/2
% AV
n = parts
r = trials
K2
0.7071
0.5231
2 1/2
{(EV + AV )}
% GRR
Parts
K3
12.
0.7071
13.
0.5231
14.
AVE
0.4467
15.
0.4030
0.3742
0.3534
0.3375
X=
16. PART
Rp=
AVERAGE
17.
(ra +
18.
x DIFF = (Max
19.
* UCLR =
R=
rb + rc ) / (# OF APPRAISERS) =
x - Min x) =
xDIFF =
R x D4 =
UCLR =
RP x K 3
Tolerance (Tol)
Tol
Upper - Lower / 6
0.3249
( Upper - Lower ) / 6
10
0.3146
100 (AV/Tol)
Appraisers
GRR
11. C
xc =
rc =
100 (EV/Tol)
% PV
ndc
100 (GRR/Tol)
100 (PV/Tol)
1.41(PV/GRR)
=
=
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
For information on the theory and constants used in the form see MSA Reference Manual, Fourth edition.
Notes:
92
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
1.
Select 10 items that represent the full range of long-term process variation
2.
Identify the appraisers they should be operator who normally use the gage
3.
If appropriate, calibrate the gage or verify that the last calibration date is valid
4.
Open the GR&R VAR(Tol) worksheet in the AIAG Core Tools file to record data, or use
MiniTab
5.
Have each appraiser assess each part 3 times preferably in random order (Minitab can
generate a random run order)
6.
7.
8.
9.
93
94
95
MSA Summary
Measurement systems must be analyzed BEFORE
embarking on process improvement activities
MSA helps understand how much observed variation is
from the measurement system
MSA will tell you about the repeatability, reproducibility
and discrimination
Sample selection is very important sample during
normal production to capture total range of process
variation
MSA assessors should be operators that would
normally use the measurement system
MSA should be done on a regular basis
96
Item
Dimension /
Specification
Part Number 0
Part Name
Design Record Change Level 0
Engineering Change Document
Specification /
Limits
Test
Date
Qty.
Tested
Measurement Method
Supplier Measurement
Results (DATA)
OK
Not
OK
Objective or Purpose
What is It?
Evidence that dimensional verifications
have been completed and results
indicate compliance with specified
requirements
97
Dimensional Results
Reviewers Checklist
98
99
Material Results
Production Part Approval
Material Test Results
ORGANIZATION:
PART NUMBER:
PART NAME:
MATERIAL SUPPLIER:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
NAME of LABORATORY:
QTY.
SUPPLIER TEST RESULTS (DATA) OK
TESTED
SPECIFICATION /
LIMITS
TEST
DATE
NOT
OK
100
ORGANIZATION
SUPPLIER / VENDOR CODE:
CODE
NAME of LABORATORY:
ECL
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
SPECIFICATION /
LIMITS
TEST
DATE
QTY.
SUPPLIER TEST RESULTS (DATA)/
OK
TESTED
TEST CONDITIONS
NOT
OK
TITLE
DATE
101
102
103
Process Capability:
The Two Voices
104
Product produced
beyond both
Upper and Lower
Spec Limits.
Product produced
above the
Upper Spec Limit.
Product produced
below the
Lower Spec Limit.
105
Capability Studies
Process Data for Co2
15
UCL=14.18
Individual Value
14
13
X=12.64
12
LCL=11.10
11
10
9
0
50
100
150
Observation Number
Individual Value
14
13
X=12.64
12
LCL=11.10
11
10
9
0
50
100
150
Observation Number
106
Step 2 Step 3
Step 4
Step 5
Step 6 Step 7
107
20
14.87
3.088
100
15
yc neuqer F
10
10
12
14
16
Mfg Hours
18
20
22
Bimodal Data
Histogram of Mfg Hours
25
19.98
1.713
100
20
Mean
StDev
N
15
20
yc neuqer F
yc neuqerF
15
10
10
5
5
16
18
20
Mfg Hours
22
Normal Data
24
-15
15
30
45
Mfg Hours
60
75
Skewed Data
108
20.19
18.87
100
109
Cp > 1.67
Cpk < 1.00
Capable,
Not Centered
Capable,
Centered
LSL
LSL
USL
USL
LSL
USL
Cp < 1.00
Cpk < 1.00
Cp < 1.00
Cpk < 0
Not Capable,
Centered
Not Capable,
Not Centered
LSL
USL
110
Acceptance Criteria
Acceptance criteria for critical vs. non-critical characteristics
Red (Bad)
Yellow (Marginal)
Green (Good)
Short-term
Long-term
<1.33
<1.00
1.33-1.67
1.00-1.33
>1.67
>1.33
Decision
111
112
113
DRAWING
NUMBER
NUMBER
PART
BUYER
NAME
APPLICATION
(VEHICLES)
E/C LEVEL
DATE
CODE
ORGANIZATION
MANUFACTURING
SUPPLIER / VENDOR
NAME
LOCATION
CODE
REASON FOR
SPECIAL SAMPLE
RE-SUBMISSION
SUBMISSION
PRE TEXTURE
ENGINEERING CHANGE
OTHER
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
PRE-TEXTURE REPRESENTATIVE
EVALUATION
SIGNATURE AND DATE
CORRECT AND
PROCEED
CORRECT AND
PROCEED
Objective or Purpose
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
METALLIC COLOR
COLOR
TRISTIMULUS DATA
DATE
TYPE
SOURCE
HUE
RED
YEL
GRN
VALUE
BLU
CHROMA
GLOSS
HIGH
LOW
BRILLIANCESHIPPING
HIGH
LOW
PART
SUFFIX DISPOSITION
IMPORTANT!
Only applies for parts with color, grain,
or surface appearance requirements
114
DRAWING
NUMBER
NUMBER
PART
BUYER
NAME
CODE
ORGANIZATION
APPLICATION
(VEHICLES)
E/C LEVEL
DATE
MANUFACTURING
NAME
SUPPLIER / VENDOR
LOCATION
CODE
REASON FOR
SPECIAL SAMPLE
RE-SUBMISSION
SUBMISSION
PRE TEXTURE
ENGINEERING CHANGE
OTHER
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
PRE-TEXTURE REPRESENTATIVE
EVALUATION
SIGNATURE AND DATE
CORRECT AND
PROCEED
CORRECT AND
PROCEED
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
COLOR
TRISTIMULUS DATA
Administrative
Section
HUE
VALUE
CHROMA GLOSS
DATE
TYPE
SOURCE
Identifies part number and description,
supplier, required approval signatures, and
dates.
RED
YEL
GRN
BLU
HIGH
LOW
METALLIC COLOR
BRILLIANCESHIPPING
HIGH
LOW
PART
SUFFIX DISPOSITION
115
DRAWING
NUMBER
NUMBER
APPLICATION
NUMBER
PART
NAME
NAME
DATE
ECL
ADDRESS
CITY
MANUFACTURING
ORGANIZATION
NAME
E/C LEVEL
CODE
ORGANIZATION
APPLICATION
(VEHICLES)
BUYER
LOCATION
SUPPLIER / VENDOR
STATE
ZIP CODE
REASON FOR
SPECIAL SAMPLE
RE-SUBMISSION
SUBMISSION
PRE TEXTURE
ENGINEERING CHANGE
CODE
OTHER
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
PRE-TEXTURE REPRESENTATIVE
EVALUATION
SIGNATURE AND DATE
CORRECT AND
PROCEED
CORRECT AND
PROCEED
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
METALLIC COLOR
COLOR
TRISTIMULUS DATA
DATE
TYPE
SOURCE
HUE
RED
YEL
GRN
VALUE
BLU
CHROMA
GLOSS
HIGH
LOW
BRILLIANCESHIPPING
HIGH
LOW
PART
SUFFIX DISPOSITION
116
TRISTIMULUS DATA
DATE
TYPE
SOURCE
HUE
RED
YEL
GRN
VALUE
BLU
CHROMA
GLOSS BRILLIANCESHIPPING
HIGH
LOW
HIGH
LOW
PART
SUFFIX DISPOSITION
COMMENTS
ORGANIZATION
SIGNATURE
PHONE NO.
DATE
AUTHORIZED CUSTOMER
DATE
REPRESENTATIVE SIGNATURE
117
Objective or Purpose
Confirm cosmetic or functional part
approval.
When to Use It
Sample parts should be delivered
WITH the PPAP submission
118
119
120
121
122
Part Number: 0
Part Name / Description
Part Family (if Applicable):
Revision Level: 0
Eaton Plant:
Part Risk Level:
Date Submitted:
Any Issue:
Note: Eaton recommends that this agreement be completed by the quoting supplier's production, quality or engineering staff. Add rows as required.
Supplier Input Data
Special
Confirm supplier (you)
Measure and input at
Print Requirements
Evaluation
Characteristics
are capable of
the completion of
(Including all Dimensions,
Measurement
/ Critical To
manufacture and meet
PPAP run
Notes and Specifications or
Technique
Quality (CTQ) the require specification
as instructed by Eaton)
(Gage used)
(Yes or No)
(Yes / No)
SPC
PpK / CpK
Comment
Specification
Change Required
Eaton Agrees
(Yes / No)
Comment
Specification
Change Required
Eaton Agrees
(Yes / No)
Comment
Specification
Change Required
- Require to fill in all the Print requirements following by the Ballooned prints with numbering.
- For complicated or family parts, only listing the exceptional dimensions or requirements is acceptable. But Ballooned prints are necessary to be attached to show all the
Print requirements have been reviewed.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
OTHER REQUIREMENTS: Please include any exceptions to print notes, referenced specifications, Gerber files, schematics, reference drawings , assembly drawings, plating,
finishing, special processes and/or packaging requirements as may be specified on drawing, purchase order or in the supplier quality manual. Add rows as required.
1
2
3
4
5
IMPORT SPECIFIC REQUIREMENTS: Add rows as required. Please refer to the Supplier Excellence Manual for further clarifications of governing requirements.
Please identify which test can be done and where (3rd party
lab / supplier plant lab / material supplier)
For material part or Casting process part, please identify
whether the product's radiation conforms with all specific
national standards. List who completed the radiation testing
(supplier plant lab or 3rd party). For other material or
process part, fill "NA" in the item
4
5
#
Caliper 1
CMM 2
3
Color Chip
4
Drop Gage
Comments
Lessons Learned
Spectrophotometer
By signing this document you (supplier) confirm that at the time of mass production you can achieve all print requirements unless otherwise noted "No" in column F above
Texture Plaques
Thread Gage
Supplier Representative Signature and Date
Eaton SDE/SQE Name & Signature Date
Eaton Engineering Name & Signature Date
Visual
x Sign Here
X Sign Here
X Sign Here
Type/Print name here
Type/print name here
Type/print name here
Type/Print Title Here
Suppliers: Type name on each page
Eaton Purchasing Name & Signature Date
x Sign Here
Type/print name here
Comments from Eaton Design Engineering or Purchasing
123
PFA (cont.)
124
PFA (cont.)
Supplier Input Data
Evaluation
Special
Confirm supplier (you)
Measure and input at
Print Requirements
Measurem
Characteristics
are capable of
the completion of
(Including all Dimensions,
ent
/ Critical To
manufacture and meet
PPAP run
Notes and Specifications or
Technique
Quality (CTQ) the require specification
as instructed by Eaton)
(Gage
(Yes or No)
(Yes / No)
used)
SPC
PpK / CpK
Supplier Comments
- Require to fill in all the Print requirements following by the Ballooned prints with numbering.
- For complicated or family parts, only listing the exceptional dimensions or requirements is acceptable. But Ballooned prints are necessary to be attached to show
all the Print requirements have been reviewed.
1
2
3
4
5
6
7
8
9
10
11
12
125
PFA (cont.)
Eaton Input Data
Eaton Agrees
(Yes / No)
Comment
Specification
Change Required
126
PFA (cont.)
1
Does the design allow the use of efficient material handling techniques?
Comments
Supplier comments for Cost improvement (Ideals for recommendation, Ex. VA/VE, substitute material, tooling, process, etc.)
By signing this document you (supplier) confirm that at the time of mass production you can achieve all print requirements unless otherwise noted "No" in column F
Texture Plaques
Supplier Representative Signature and Date
Eaton SDE/SQE Name & Signature Date
x Sign Here
X Sign Here
Type/Print name here
Type/print name here
Type/Print Title Here
Suppliers: Type name on each page
Eaton Purchasing Name & Signature Date
x Sign Here
Type/print name here
127
Gage Plan
Gage Plan
Supplier
Part Revision
Manufacturing Location
Document Revision
Part Name
Eaton Plant
Print Balloon
No.
example
Supplier
Characteristic
(Dimension and
Char. Type
tolerance)
Critical
Eaton Quality
Suppliers
measurement
method
CMM
CMM
Team
Is measurement
method
acceptable?
Yes
128
Supplier Representative:
Phone number:
Correlation Date:
Drawing Number:
Manufacturing Location
Part Name
Part Number or Specification 0
Eaton Plant
Eaton
part/Assembly
number
Print feature
name
Example
Ball diameter
0.0025
0.0025
Example
Ball diameter
0.0025
0.0025
Example
Ball diameter
0.0025
0.0025
Example
Ball diameter
0.0025
0.0025
Sample
Upper Tolerance (+) Lower Tolerance (-) Total Tolerance Nominal target
Number
0.005
0.005
0.005
0.005
5.556
5.556
5.556
5.556
Bonus
Tolerance
Y/N
Eaton Measuring
equipment type
Eaton reading
5.5592
5.5612
5.5595
5.5597
Supplier
Measuring
Supplier reading
equipment type
Non contact laser
Non contact laser
Non contact laser
Non contact laser
5.5586
5.5601
5.5581
5.5582
Delta
% of tolerance
(if value is > or = to 25% or -25%,
correlation improvement
is recommended)
0.00063
0.00113
0.00142
0.00151
13%
23%
28%
30%
129
Review Date
Mfg. Location
Status Intended for Use
Element
G/Y/R
Prior to
1
g
PPAP /
Production Run
Recovery Plan/Comments
(if status is Red or Yellow)
Readiness Criteria
2.1
g
g
Production Run
Production Run
Comments
Was an APQP project established and have required PPAP activities been completed
in the APQP process? For those activates that remain open, are they planned to be
completed in line with the APQP timeline?
Supplier
Complete
Due Date
Commodity
Responsible Person's
Name
Eaton
Reviewed
Did the supplier complete and did the plant / approving authority review the PPAP
package in details and there are no outstanding issues pending?
a. Process Capability
130
Dated
Dated
Yes
No
Dated
Customer Name/Division
Street Address
Buyer/Buyer Code
City
Weight (kg)
Region
Postal Code
What is It?
Required document in which the
supplier confirms the design and
validation of manufacturing
processes that will produce parts
to specification at a specific rate
Objective or Purpose
Used to :
Country
Application
MATERIALS REPORTING
Has customer-required Substances of Concern information been reported?
Yes
No
Yes
No
n/a
Engineering Change(s)
Correction of Discrepancy
Yes
NO
appearance criteria
When to Use It
Prior to shipping production parts
Yes
No
n/a
Date
Phone No.
Title
Fax No.
E-mail
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Approved
Rejected
Other
Customer Signature
Print Name
Date
Customer Tracking Number (optional)
131
Dated
Dated
Yes
No
Customer Name/Division
Street Address
Buyer/Buyer Code
Region
Postal Code
Country
Dated
City
Weight (kg)
Application
132
Dated
Dated
Yes
No
Customer Name/Division
Street Address
Buyer/Buyer Code
Region
Postal Code
Country
Dated
City
Weight (kg)
Application
133
ORGANIZATION
CODE
CUSTOMER
DIVISION
Customer Name/Division
ADDRESS
Street Address
Buyer/Buyer Code
CITY
City
STATE
ZIP
Region
Postal Code
APPLICATION
Country
Application
MATERIALS REPORTING
Has customer-required Substances of Concern information been reported?
Yes
No
Yes
No
n/a
Engineering Change(s)
Correction of Discrepancy
Here
thesamples
supplier
is required
todata
identify
it
Level 3 - Warrant with
product
and complete
supporting
submittedhow
to customer.
Level 4 - Warrant and
requirements
as defined by customer.
hasother
reported
Substances
of Concern:
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
dimensional measurements
The results for
Yes
NO
appearance criteria
134
ORGANIZATION
CODE
CUSTOMER
DIVISION
Customer Name/Division
ADDRESS
Street Address
Buyer/Buyer Code
CITY
City
STATE
ZIP
Region
Postal Code
APPLICATION
Country
Application
MATERIALS REPORTING
Has customer-required Substances of Concern information been reported?
Yes
No
Yes
No
n/a
Engineering Change(s)
Correction of Discrepancy
135
ORGANIZATION
CODE
CUSTOMER
DIVISION
Customer Name/Division
ADDRESS
Street Address
Buyer/Buyer Code
CITY
City
STATE
ZIP
Region
Postal Code
APPLICATION
Country
Application
MATERIALS REPORTING
n/a
Engineering Change(s)
Correction of Discrepancy
Yes
NO
appearance criteria
136
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
dimensional measurements
The results for
NO
appearance criteria
Yes
No
Date
Phone No.
Title
n/a
555-555-5555
Fax No.
The supplier
declares that
the PPAP submission
Approved
Rejected
Other
PPAP Warrant Disposition:
is based on production processes run at a
Customer Signature
Date
normal or planned production rate.
Print Name
Customer Tracking Number (optional)
The supplier states
the production rate.
The supplier indicates that any customer owned
tooling is properly identified
2014 Eaton. All Rights Reserved.
137
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
dimensional measurements
The results for
appearance criteria
Prior to submitting
the supplier
Yesthe PPAP,
NO
These results meet all design record requirements:
(If "NO" - Explanation Required)
representative signs the warrant, indicating the
Mold / Cavity / Production Process
part meets Eaton requirements
DECLARATION
I affirm that the samples represented
this warrant then
are representative
of our
whichthe
werePPAP
made by a process that meets
The by
customer
approves
or parts,
rejects
all Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the
and signs to confirm the decision
production rate of ____/____ hours. I also certify that documented evidence of such compliance is on file and available for your
review. I have noted any deviation
from
this declaration
below.
The
customer
approved
PSW is a prerequisite for
EXPLANATION/COMMENTS: production shipments
Is each Customer Tool properly tagged and numbered?
Yes
No
n/a
Date
Phone No.
Title
555-555-5555
Fax No.
E-mail
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Approved
Rejected
Other
Customer Signature
Print Name
Date
Customer Tracking Number (optional)
138
139
140
PPAP Summary
PPAP checks that any process changes have
been properly designed and validated, and the
resulting process is capable of repeatedly
producing parts to specification
The PPAP elements should be part of your Quality
Management System. PPAP shouldnt require
much extra effort, because youve already done
the work internally to manage your changes.
Reacting to later issues with the product or
process can be expensive and time-consuming!
2014 Eaton. All Rights Reserved.
141
142