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What is PPAP?
NCR Confidential 2
Purpose of PPAP
NCR Confidential 3
When is PPAP Required?
New part
Engineering change(s)
Correction of discrepancy
NCR Confidential 4
Benefits of PPAP Submissions
NCR Confidential 5
Production Run
Production employees
Production rate
Production process
NCR Confidential 6
Run @ Rate
NCR Confidential 7
Official PPAP Requirements
1. Design Records
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA) applied in special situations
5. Process Flow Diagram
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
Now, lets take a closer look
14. Sample Production Parts
at NCRs requirements
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)
NCR Confidential 8
NCRs PPAP Requirements
1. Design Records
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA) applied in special situations
5. Process Flow Diagram
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
Supplier shall submit
13. Appearance Approval Report (AAR) these 12 items and
14. Sample Production Parts retain a copy of records
15. Master Sample at appropriate locations
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW) NCR calls this the Production Warrant
NCR Confidential 9
NCRs PPAP Requirements
1. Design Records
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA) applied in special situations
5. Process Flow Diagram
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
Supplier shall retain
13. Appearance Approval Report (AAR) these 6 items at
14. Sample Production Parts appropriate locations,
15. Master Sample and make readily
available upon request
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW) NCR calls this the Production Warrant
NCR Confidential 10
PPAP Submission Levels
NCR Confidential 11
PPAP Submission Level Table
S = The supplier shall submit to NCR and retain a copy of records or documentation items at appropriate locations.
R = The supplier shall retain at appropriate locations and make readily available to NCR upon request.
* = The supplier shall retain at appropriate locations, and submit to NCR upon request. NCR will identify what is
needed for submission.
NCR Confidential 12
Definition of Risk
High Risk
Parts associated with multiple critical features, complex
design, or high end technology that is not yet established in
the general manufacturing environment
Medium Risk
Parts that have at least one critical feature
Low Risk
Parts that have no critical features and can be manufactured
by any manufacturer in the commodity category
NCR Confidential 13
Submission Level Requirements
New Parts
Level 2 is required for Low Risk Parts
Part Changes
Level 3 is required for Parts produced at a new or
additional location
NCR Confidential 14
PPAP Status
Approved
The part meets all NCR requirements
Interim Approval
Permits shipment of part on a limited time or piece quantity basis
Rejected
The part does not meet NCR requirements, based on the
production lot from which it was taken and/or accompanying
documentation
NCR Confidential 15
Electronic Submission Requirements
NCR Confidential 16
NCR PPAP Playbook
NCR Confidential 17
PRODUCTION WARRANT
NCR Confidential 18
Production Warrant
Safety and/or Government Regulation Yes No Purchase order No. Weight (kg)
Objective or Purpose
Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No
Used to :
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part processing
Correction of Discrepancy Parts Produced at New or Additional Location
Level 2 - Production Warrant, product samples, and dimensional results submitted to NCR
Level 3 - Production Warrant, product samples, and complete supporting data submitted to NCR
Level 4
Level 5
-
-
Production Warrant and other requirements as defined by NCR
Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location
declare that the parts meet
SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
specification
These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)
When to Use It
Mold / Cavity / Production Process:
DECLARATION
NCR Confidential 19
Production Warrant
Production Warrant
Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No
NCR Confidential 20
Production Warrant
Production Warrant
Safety and/or Government Regulation Yes No Purchase order No. Weight (kg)
Parts Identified with Appropriate Marking Codes
UL = Aid
Checking Underwriters
No. Laboratories safety standards
Engineering Change Level Dated
Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No
NCR Confidential 21
Production Warrant
REQUESTED SUBMISSION LEVEL (Check one based on NCR requirements) Identify the submission level
Mold / Cavity / Production Process requested by NCR
If production
Level 1 - parts will
Production be
Warrant andproduced from
Appearance Approval Report (if applicable) submitted to NCR
more than
Level 2 one mold,Warrant,
- Production cavity, tool,
product samples,die,
and dimensional results submitted to NCR
pattern, or
Level 3 production process,
- Production Warrant, Submission
product the and
samples, supplier
Results
complete supporting data submitted to NCR
shall complete
Level 4 a dimensional
- Production Check
Warrant and evaluation
other requirements on by NCR boxes
the appropriate
as defined
one part from
Level 5
each. The specific molds,
- Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location
lines, etc. shall then be identified here.
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)
Mold / Cavity / Production Process:
NCR Confidential 22
Production Warrant
Explanation / Comments Declaration Declaration
Provide any explanatory Entercommentsthe Affirmation
number onof that
the pieces the samples represented
submission results or manufactured by the during
any deviations warrant the are representative and
Supplier Authorized Signature
significant were made by run
production a process that meets NCRs
from the Declaration. Attach additional
A DECLARATION
responsible supplier official,
PPAP after verifying
requirements
and the time (in hours) taken
information as appropriate.
that the results show for theconformance
significantto all NCR
production run
I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all of NCR's
requirements and that all required documentation
Production Part Approval Process requirements. I further affirm that these samples were produced at the production rate of
is _____
available, shall
pieces / _____ hours. Iapprove
also certify that the declaration
documented evidence of such compliance is on file and available for review. I have noted
any deviations from this declaration below.
EXPLANATION/COMMENTS: For NCR Use Only
To be completed by appropriate
PPAP Warrant Disposition NCR Supplier Quality Engineer
NCR Signature
Approved, Rejected,
Supplier Authorized Signature Other Date
Signed by NCR Supplier
Print Name Title
Quality Engineer
Email Phone No.
NCR Confidential 23
Production Warrant
Reviewers Checklist
Must be completely filled out
Must be signed by the supplier
P/N must match the PO
Submitted at the correct revision level
Submitted at the correct submission level
Specify the reason for submission
NCR Confidential 24
AUTHORIZED ENGINEERING
CHANGE DOCUMENTS
NCR Confidential 25
Authorized Engineering Change Documents
Specifications
Feasibility studies
Sub-assembly drawings
NCR Confidential 26
PROCESS FLOW DIAGRAM
NCR Confidential 27
Process Flow Diagram
What is It?
Operator
Separate Cutting Evaluate for
A visual diagram of the entire
process from receiving through
Tags Corrective Action
(31)
No
Operator
Remove Small
Plies from the
Cutting Table
Operator
Move to Kitting
Table
(37)
Operator
Tag Small Plies
(38)
Objective or Purpose
(36)
Operator
Small Plies
inspection, handling)
Form
with Initial
Information
Rework, scrap
BB or GB No this project Dept GB/BB/MBB
within your
area?
Monitor Progress
Begin/Work Yes Monitor Progress Begin/Work
through Power
Project through Bi- Project
Steering and Finance Approval
Weekly Updates
Monthly and Signature Finance Approval
Follow DMAIC or and Monthly Follow DMAIC or
Financial and Signature
DFSS process Do you Reviews DFSS process
Reviews
No have BB/GB to
Assist/Work the
project?
Master Form Will
Complete Project Generate Yes Complete Project
(Has to be fully Master Form Will (Has to be fully
Contract
Documented Generate Documented)
Contract
When to Use It
Yes Is Hard
Savings > $???
Does the
Other Required Other Required
done
Project Involve No
Signatures: Signatures:
Champion: Dir T&E >2 Groups in Champion: Dir T&E
Eng?
Process Owner Process Owner
Project Owner Project Owner
Dept BB or MBB Yes Dept BB or MBB
NCR Confidential 28
Process Flow Diagrams
Product and
Inspect
Item #
Item #
Move
Store
Operation
STEP Process Control Methods
Description
Characteristics
10
11
12
NCR Confidential 29
Process Flow Diagram - Example
70 60 50 40 30
Not ok , Rejected
** Inspection as per 100%
Inspection as If Rejected If rework
Opertion layout Re-inspection
per RIQP possible Rework
Not ok , Rejected
Return to Note : Not ok Ok
supplier Tags to be provided
for OK, Rework, Inspection Scrap Next
& Rejection operation
NCR Confidential 30
Star Exercise
Distribute supplies
Paper for Stars
Scissors
NCR Confidential 31
Process Flow Diagram Star Exercise
Paper Star
Incoming Final
Inspection Folding Cutting Folding Tucking Inspection
05 10 15 20 25 30
Patrol Insp
Report
Shipping Packing
40 35
OK
Not OK
NCR Confidential 32
Process Flow Diagrams
Reviewers Checklist
Process Flow must identify each step in the process
Should include abnormal handling processes
Scrap
Rework
Process Flow must include all phases of the process
Receiving of raw material
Part manufacturing
Offline inspections and checks
Assembly
Shipping
NCR Confidential 33
PROCESS FMEA
NCR Confidential 34
Process FMEA (PFMEA)
Action Re sults
O D
Item / O D
S Potential Cause(s)/ c Curre nt De sign e R. Re sponsibility &
Objective or Purpose
Identifies potential failure modes,
causes, and effects. Inputs come
from the process flow diagram.
Identifies key inputs which
positively or negatively affect
quality, reliability and safety of a
product or process.
When to Use It
After completion of the process
IMPORTANT! flow diagram.
The PFMEA should be completed Prior to tooling for production
using a cross-functional team!
NCR Confidential 35
FMEA Origin
NCR Confidential 36
Process FMEA (PFMEA)
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
Action Results
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process Recommended Responsibility
Sev
R.P.N.
Process Step Effect(s) of Actions
Occ
Sev
Det
Mode Mechanism(s) Controls Actions & Target Date
Failure Taken
of Failure
NCR Confidential 37
PFMEA - Step 1
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Failure Modes Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
For each Process
Failure Input,
of Failure
determine the ways in
which the
Op 70: Manual Insufficient wax Allows integrity 7 inputManually
can go 8 Variables check 5 280
application of coverage over breach wrong.
of inner inserted spray for film
wax inside door specified surface door panel head not thickness; Visual
panel inserter far check for
Corroded interior enough coverage
lower door
panels
Spray head 5 Variables check 5 175
Deteriorated life clogged: for film
Using the completed of door leading - Viscosity too thickness; Visual
Process Flow Diagram, to: high check for
enter the process step. - Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
to rust through low and after idle
paint over time periods and
- Impaired preventative
function of maintenance
interior door program to clean
hardware heads
TIPS
There should be at least one failure mode for each input.
NCR Confidential 38
PFMEA - Step 2
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
Failure
of Failure
Op 70: Manual Insufficient wax Allows integrity 7 Manually 8 Variables check 5 280
application of coverage over breach of inner inserted spray for film
wax inside door specified surface door panel head not thickness; Visual
panel inserter far check Effects
Potential Failure for
Corroded interior enough coverage
For each Failure Mode,
lower door
panels determine what effect
the specific failure
Spray head 5 Variables check 5 175
Deteriorated life could
clogged:
have on
for film
the
of door leading process
- Viscosity too output.
thickness; Visual
to: high check for
- Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
to rust through low and after idle
paint over time periods and
- Impaired preventative
function of maintenance
interior door program to clean
TIPS hardware heads
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.
NCR Confidential 39
PFMEA - Step 3
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
Failure
of Failure
Op 70: Manual Insufficient wax Allows integrity 7 Manually 8 Variables check 5 280
application of coverage over breach of inner inserted spray for film
wax inside door specified surface door panel head not thickness; Visual
panel inserted far check for
Potential Causes Corroded interior enough coverage
lower door
For each Failure Mode,panels
determine the possible
Spray head 5 Variables check 5 175
cause of the failure.Deteriorated life clogged: for film
of door leading - Viscosity too thickness; Visual
to: high check for
- Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
to rust through low and after idle
paint over time periods and
- Impaired preventative
function of maintenance
interior door program to clean
hardware heads
TIPS
There should be at least one potential cause for each failure mode.
NCR Confidential 40
PFMEA - Step 4
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
Failure
of Failure
Op 70: Manual Insufficient wax Allows integrity 7 Manually 8 Variables check 5 280
application of coverage over breach of inner inserted spray for film
wax inside door specified surface door panel head not thickness; Visual
panel Current Controls inserter far check for
For each
Corroded potential
interior enough coverage
cause, list the current
lower door
methodpanelsused for
preventing or detecting
Spray head 5 Variables check 5 175
Deteriorated
failure. life clogged: for film
of door leading - Viscosity too thickness; Visual
to: high check for
- Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
to rust through low and after idle
TIPS paint over time periods and
- Impaired
This step in the FMEA begins to identify initial shortcomings
function of
preventativeor gaps in the
maintenance
current control plan. interior door program to clean
hardware
If a procedure exists, enter the document number. heads
If no current control exists, list as none.
NCR Confidential 41
PFMEA - Step 5
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
Failure
of Failure
Assign Severity
Op 70: Manual(How serious
Insufficient waxis the
Allows integrity 7 Manually 8 Variables check 5 280
application effect
of coverage over
if it fails?) breach of inner inserted spray for film
wax inside door specified surface door panel Assign
headDetection
not thickness; Visual
panel (How easily
inserter far can thecheck for
Corroded interior enough
cause or failure coverage
lower door mode be detected?)
panels
Spray head 5 Variables check 5 175
Deteriorated life
Assign Occurrence clogged: for film
of door leading
(How likely is the - Viscosity too thickness; Visual
to:
cause to occur?) high check for
- Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
to rust through low and after idle
paint over time periods and
- Impaired preventative
function of maintenance
interior door program to clean
hardware heads
NCR Confidential 42
PFMEA - Definition of Terms
NCR Confidential 43
An Example of Rating Definitions
Severity Occurrence Detection*
Rating
Hazardous Very high and Cannot detect
High 10 without almost or detection
warning inevitable with very low
probability
Loss of primary High repeated Remote or low
function failures chance of
detection
Loss of Moderate Low detection
secondary failures probability
function
Minor defect Occasional Moderate
failures detection
probability
Low 1 No effect Failure unlikely Almost certain
detection
*If No Controls Exist, Detection = 10
NCR Confidential 44
PFMEA - Step 6
Potential
Potential
R.P.N.
Occur
Detec
Class
Potential Failure Cause(s)/ Current Process
Sev
Process Step Effect(s) of
Mode Mechanism(s) Controls
Failure
of Failure
Op 70: Manual Insufficient wax Allows integrity 7 Manually 8 Variables check 5 280
application of coverage over breach of inner inserted spray for film
wax inside door specified surface door panel head not thickness; Visual
panel inserter far check for
Calculate the Risk Priority Number
Corroded interior enough coverage
lower door
RPN = Severity x Occurrence x Detection
panels
Spray head 5 Variables check 5 175
Deteriorated life clogged: for film
of door leading - Viscosity too thickness; Visual
to: high check for
TIPS - Unsatisfactory - Temp too low coverage; Test
appearance due - Pressure too spray at start-up
The RPN is used to prioritize the
to rust most
through critical
low risks identified
and after idlein the first half
paint over time
of the FMEA. - Impaired
periods and
preventative
function of maintenance
High RPNs (125 or above) are interiorflags
door to take effort to reduce
program tothecleancalculated
risk. hardware heads
NCR Confidential 45
Analyzing the PFMEA
60 100
50
80
40
Percent
60
Count
30
40
RPN Thresholds
20
20
10
Count 10 9 8 6 4 4 4 4 2 2 2 2 3
scores
Percent
Cum %
17
17
15
32
13
45
Pareto Chart
10
55
7
62
7
68
7
75
7
82
3
85
3
88
3
92
3
95
5
100
NCR Confidential 46
PFMEA Remediation Guidelines
NCR Confidential 47
FMEA Step 7
R.P.N.
Potential Failure Recommended Responsibility &
R.P.N.
Process Step Effect(s) of
Occ
Sev
Det
Mode Actions Target Date Actions Taken
Failure
Op 70: Manual Insufficient wax Allows integrity 280 Add positive Mfg. Eng. By Stop added, 7 2 5 70
application of coverage over breach of inner depth stop to 5/10/10 sprayer checked
wax inside door specified surface door panel sprayer on-line
panel Automate Mfg. Eng. By Rejected due to
Corroded interior spraying 5/25/10 complexity of
For the high RPN numbers, lower door different doors on
determine the panels the same line
recommended actions. 175 Use DOE on Mfg. Eng. By Temp and press 7 1 5 35
Deteriorated life viscosity vs. 5/31/10 limits were
of door leading temp vs. determined and
to: pressure limit controls
- Unsatisfactory have been
appearance due installed - Control
to rust through charts show
paint over time process is in
- Impaired control Cpk =
function of 1.85
interior door
hardware
NCR Confidential 48
FMEA Steps 8 and 9
Action Results
Potential
R.P.N.
Potential Failure Recommended Responsibility &
R.P.N.
Process Step Effect(s) of
Occ
Sev
Det
Resp
Mode (responsibility)
Failure
Actions Target Date Actions Taken
Assign a specific person
Op 70: Manual who will
Insufficient wax be responsible
Allows integrity 280 Add positive Mfg. Eng. By Stop added, 7 2 5 70
application of for recommended
coverage actions.
over breach of inner depth stop to 5/10/10 sprayer checked
wax inside door specified surface door panel sprayer on-line
panel Automate Mfg. Eng. By Rejected due to
Corroded interior spraying 5/25/10 complexity of
Actions
lower door Taken different doors on
As actions are identified
panels the same line
and completed, 175 Use document
DOE on Mfg. Eng. By Temp and press 7 1 5 35
Deteriorated life viscosity vs. 5/31/10 limits were
of in
doorthe Actions
leading Taken
temp vs. determined and
column.
to: pressure limit controls
- Unsatisfactory have been
appearance due installed - Control
to rust through
paint over time
SEV, OCC, DET,charts
RPN show
process is in
- Impaired As actions are control
complete
Now recalculate your RPNs function of
reassess Severity,
1.85
Cpk =
NCR Confidential 49
Summary Steps To Complete a FMEA
1. 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. Identify potential Causes of each Failure Mode.
4. List the Current Controls for each Cause.
5. Assign Severity, Occurrence and Detection ratings after creating a
ratings key appropriate for your project.
6. Calculate RPN.
7. Determine Recommended Actions to reduce High RPNs.
8. Take appropriate Actions and Document.
9. Recalculate RPNs.
10. Revisit steps 7 and 8 until all the significant RPNs have been
addressed.
NCR Confidential 50
PFMEA Exercise
Instructions
30 Minutes
NCR Confidential 51
Process FMEA (PFMEA)
NCR Confidential 52
Process FMEA (PFMEA)
Reviewers Checklist
Verify there is a system for prioritizing risk of failure
such as RPN numbers of 125 or above
NCR Confidential 53
CONTROL PLAN
NCR Confidential 54
Control Plan
What is It?
A document that describes how to
control the critical inputs to
continue to meet customer
expectations of the output.
Objective or Purpose
Primary reference source for
minimizing process and product
variation.
Description of how teams should
react to out-of-control situations.
NOTE
Since processes are expected to be continuously When to Use It
updated and improved, the control plan
Implementation of new process
is a living document!
Following a process change
NCR Confidential 55
Control Plan
Tool Interaction
Key S O D R E
6 Sigma Project Project Idea Department/Group Project Potential Potential
High Level Process Map High Level Process Map Process Step Process E Potential Causes C Current Controls E P O
Failure Mode Failure Effects
Input V C T N C
Fill Out M aster
Process Steps
Form
with Initial
Information Receive Checks Delay internal AR balance does Inadequate None Investigate mail room
Oth er Required
Signatures:
Other Required
Sig natures:
Payment mail not go down staffing in mail staffing and associated
Get WO Assigned
6 Sig ma Assigns
Project Number
Segmen t CEO
Champion
Champion:
Process Owner
Group Assigns
Project Number
Get DLN
Assigned
7 room 7 10 490 processes
Process Owner Prefer to wo rk Project Owner
BB o r GB No this pro ject Dep t GB/BB/MBB
within your
area?
Monitor Progress
Begin/Work Mon itor Progress B egin/Wo rk
Project
through Power
Steering an d Finance Approval
Yes
through Bi-
Weekly Up dates
Project Identify Wire Information not AR balance is Customer or bank Acct identifies problem Poka-Yoke wire transer
Monthly and Signature Finan ce Approval
F ollow DMAIC or
DFSS process
Financial
Reviews
No
Do you
and Signature
and Monthly
Reviews
Follow DM AIC or
DFSS process Customer Transfer supplied past due did not include when trying to apply process
have BB/GB to
Assist/Work the
p roject?
reference name and/or payment
Comp lete Project
Master Fo rm Will
Yes Complete Project line 10 account info on 5 5 250
Generate
(Has to be fully C ontract Master Form Will (H as to be fully
Documented Generate
Contract
Documen ted)
wire transfer
Yes Is Hard
Savin gs > $???
Final Project
Review
Enter Remaining
Info rmatio n on
Master Form
6 Sigma
Project No
Final Project
R eview
Identify Invoice Checks Incorrect Invoice shows Customer error Customer might catch Provide payment stub
invoice outstanding (AR it when reviewing the with statement for each
balance does go 5 5 next statement 10 250
Does the Department
Project Invo lve
Only Your
Yes
or Group
Enter Remaining
Information on
Master Form
supplied invoice
Project
down)
Group?
New/Revised Process
Finance App roval F inance Approval
and Signatu re an d Signature
No
Identify Invoice Checks Invoice number Invoice shows Customer error Acct identifies problem Provide payment stub
Other R equired
Signatures:
Does the
Project Invo lve No
Other Required
Signatures:
not supplied outstanding (AR when trying to apply with statement for each
balance does go 5 10 payment 5 250
>2 Group s in
invoice
C hampion: Dir T& E Champion : Dir T&E
Process Owner Eng ? Process Owner
Project Owner Project Owner
D ept BB or MBB Yes Dept BB or MBB
down)
Steps
Complete all Complete all
Does the
Documentation Close Yes No Close Do cumentatio n
Project Invo lve
includin g a includ ing a
Project >3 Depts. Project
(1) Page Close- (1) Page Close-
o utside Eng?
out Sheet out Sheet
Process FMEA
Process Flowchart
Control Plan
NCR Confidential 56
NCRs Control Plan
CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
NCR Confidential 57
Control Plan
3 Distinct Phases
CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
NCR Confidential 58
Control Plan
Administrative Section
CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
Administrative Section
Identifies part number and description,
supplier, required approval signatures,
and dates.
NCR Confidential 59
Control Plan
CONTROL PLAN
Characteristics
Part/Process Define the characteristics
UsePrototype Pre-Launch
this area to define Production
of the product or process
Controlpart/process
Plan Number number and Key Contact/Phone Date:(Org.) Date (Rev.)
description.
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
Machine/Tools
List the machine, device, jig, or tools
that will be used in the
manufacturing process
NCR Confidential 60
Control Plan
Sample Size
What is the size of the
sample you should gather
CONTROL PLAN data from?
Prototype Pre-Launch Production
Control Plan Number
Specifications/Tolerance
Key Contact/Phone Date:(Org.) Date (Rev.)
Use this area to define upper/lower
Part Number/Latest Change Level spec limits for each
Core Teamcontrol element. Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
Measurement Technique
For each line in the control plan, list the
measurement procedure that will be
Frequency
used (may list R&R Gage Plan or Poka- Define the frequency for
Yoke). which the measurement
will be taken.
NCR Confidential 61
Control Plan
Control Method
Method that will be used
CONTROL PLAN to control the process
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
Reaction Plan
Actions to be taken if
controls fail
NCR Confidential 62
Control Plan
Audit Plans
Audit plans should be included in the control plan as a
separate line.
NCR Confidential 63
Control Plan Example
3 Distinct Phases
Production
Measurement Technique
Product = Sensor continuity check
Process = Test sampling lab environment
NCR Confidential 64
Control Plan Exercise
Instructions
Open the PPAP Training Templates.xls file, then select
the Control Plan worksheet.
Using the completed Star Process Flow Diagram
(process steps 20 and 25) and the completed PFMEA,
complete 2 rows of the Control Plan.
20 Minutes
NCR Confidential 65
Control Plan
Reviewers Checklist
Use process flow diagram and PFMEA to build the control
plan; keep them aligned
NCR Confidential 67
Measurement System Analysis (MSA)
What is It?
An MSA is a statistical tool used to
determine if a measurement system
is capable of precise measurement.
Objective or Purpose
To determine how much error is in
the measurement due to the
When to Use It measurement process itself.
On the critical inputs and outputs Quantifies the variability added by
prior to collecting data for analysis. the measurement system.
For any new or modified process in Applicable to attribute data and
order to ensure the quality of the variable data.
data.
IMPORTANT!
Who Should be Involved Measurement System Analysis is
an analysis of the measurement
Everyone that measures and makes process, not an analysis of the
decisions about these measurements people!!
should be involved in the MSA.
NCR Confidential 68
Attribute and Variable MSA
NCR Confidential 69
Measurement System Analysis (MSA)
Measurement
The observed variation in System
process output Variation
measurements is not
simply the variation in the
process itself; it is the
variation in the process
Observed
plus the variation in Variation
measurement that results
from an inadequate
measurement system.
Process
Variation
NCR Confidential 70
Measurement System Analysis (MSA)
Observed Variation
Measurement
System
Variation
Observed
Variation
The output of the process
measured by:
NCR Confidential 71
Measurement System Analysis (MSA)
Precision Repeatability
(Variability)
Reproducibility
Measurement
System
Variation
Linearity
Observed Accuracy
(Central Bias
Variation Location)
Stability
Process
Variation Calibration addresses accuracy
NCR Confidential 72
Measurement System Analysis (MSA)
Precision Repeatability
(Variability)
Reproducibility
Measurement
System
Variation
Linearity
Accuracy
Observed (Central Bias
Variation Location)
Stability
Resolution
Error in Resolution
The inability to detect small
changes.
Possible Cause
Wrong measurement device
selected - divisions on scale
not fine enough to detect
changes.
NCR Confidential 74
Measurement System Analysis (MSA)
Repeatability
Error in Repeatability
The inability to get the same
answer from repeated
measurements made of the
same item under absolutely
identical conditions.
Possible Cause
Lack of standard operating
procedures (SOP), lack of
training, measuring system
variablilty.
Equipment Variation
NCR Confidential 75
Measurement System Analysis (MSA)
Reproducibility
Error in Reproducibility
The inability to get the same
answer from repeated
measurements made under
various conditions from
different inspectors.
Possible Cause
Lack of SOP, lack of training.
Appraiser Variation
NCR Confidential 76
Variable MSA Gage R&R Study
AV or Appraiser Variation
Overall % GRR
NCR Confidential 77
Variable MSA NCRs Gage R&R Form
Tolerance analysis
Average range 0.000 Repeatability (EV) #N/A #N/A
X-bar range #DIV/0! Reproducibility (AV) #DIV/0! #DIV/0!
Repeatability and Reproducibility (R&R) #N/A #N/A
Control limit for individual ranges #N/A
Note: any ranges beyond this limit may be the result
of assignable causes. Identify and correct. Discard
values and recompute statistics.
NCR Confidential 78
Variable MSA Gage R&R Steps
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10
1. Select 10 items that represent the full range of long-term process variation.
2. Identify the appraisers.
3. If appropriate, calibrate the gage or verify that the last calibration date is
valid.
4. Open the Gage R&R worksheet in the PPAP Playbook to record data.
5. Have each appraiser assess each part 3 times (trials first in order, second
in reverse order, third random).
6. Input data into the Gage R&R worksheet.
7. Enter the number of operators, trials, samples and specification limits
8. Analyze data in the Gage R&R worksheet.
9. Assess MSA trust level.
10. Take actions for improvement if necessary.
NCR Confidential 79
Steps 1 and 2: Variable MSA - Gage R&R
NCR Confidential 80
Steps 3 and 4: Variable MSA Gage R&R
date is valid.
NCR Confidential 81
Step 5: Variable MSA Gage R&R
NCR Confidential 82
Steps 6 and 7: Variable MSA Gage R&R
NCR Confidential 83
Steps 8 and 9: Variable MSA Gage R&R
NCR Confidential 84
Step 10: Variable MSA Gage R&R
NCR Confidential 85
Variable MSA Gage R&R Example
Problem Statement
The sulfuric acid concentration in process tank 8 is measured at least
once per day
Additions/deletions of chemicals and decisions to shut down the
process are dependent on these results.
Based on current data, we need to do an MSA.
MSA Process
A Gage R&R was conducted in order to validate
the process.
MSA Parameters
(3) Operators
(3) Trials
(10) Samples
NCR Confidential 86
Variable MSA Gage R&R Example
Entered upper and
Entered the number lower specification
of operators, trials, limits
and samples Gage Repeatability and operators
Chose 3 to
Reproducibility
be appraisers
This spreadsheet is designed for up to three operators, three trials, and ten samples. Enter data ONLY in gray shaded cells.
Sample # 1
Trial
2 3 Range 1
Trial
2 3
Had each appraiser
Range 1
Trial
2 3 Range
1 25.250 measure each
25.540 25.390 0.290 25.390 25.390 25.390 0.000 25.680 26.330 26.520 0.840
2 25.420 25.540 24.960 0.580 25.540 25.520 25.470 0.070 26.380 26.130 25.960 0.420
3 22.370 sample 3 times
22.370 22.670 0.300 22.220 22.180 22.220 0.040 22.670 22.810 22.670 0.140
4 24.960 25.250 25.110 0.290 25.110 25.680 25.920 0.810 25.680 26.200 25.540 0.660
5 25.540 25.540 25.820 0.280 25.540 25.680 25.680 0.140 25.730 25.960 25.890 0.230
6 24.610 Results calculated
25.110 24.820 0.500 24.960 26.700 25.110 1.740 25.390 25.540 25.960 0.570
7 24.440 24.260 24.110 0.330 25.250 25.540 25.420 0.290 25.250 25.830 25.390 0.580
8 26.100 automatically
26.800 26.100 0.700 25.540 25.540 25.820 0.280 25.110 25.680 25.920 0.810
9 25.390 25.390 25.390 0.000 26.380 26.660 26.220 0.440 25.250 25.540 25.390 0.290
10 25.680 25.820 25.540 0.280 23.900 25.250 25.110 1.350 24.200 23.870 22.960 1.240
Range average 0.355 0.516 0.578
Sample average 25.043 25.211 25.248
Selected 10 samples
to be measured Tolerance analysis
Average range 0.483 Repeatability (EV) 1.4732 29.46%
X-bar range 0.205 Reproducibility (AV) 0.4827 9.65%
Repeatability and Reproducibility (R&R) 1.5502 31.00%
Control limit for individual ranges 1.2461
Note: any ranges beyond this limit may be the result
of assignable causes. Identify and correct. Discard
values and recompute statistics.
NCR Confidential 87
Variable MSA Gage R&R Example
Repeatability
Average range = 0.483
(EV) Repeatability (EV) 1.4732
Tolerance analysis
29.46%
% Tolerance*
Reproducibility
X-bar range =0.205
(AV) Reproducibility (AV) 0.4827 9.65%
Equipment Variation
Repeatability & Repeatability and Reproducibility (R&R) 1.5502 31.00%
Appraiser Variation
30%
Control limit for individual ranges 1.2461
Reproducibility = R&R Note: any ranges beyond this limit may be the result
% Tolerance is > 30%
of assignable causes. Identify and correct. Discard
10%
values and recompute statistics.
MSA fails!
NCR Confidential 88
Gage R&R Exercise - Setup Instructions
NCR Confidential 89
Gage R&R Exercise - Dimensional Information
Dimension
NCR Confidential 90
Gage R&R Exercise Inspection Instructions
NCR Confidential 91
Gage R&R Exercise - Analysis Instructions
45 Minutes
NCR Confidential 92
Tips and Lessons Learned
NCR Confidential 93
MSA
Reviewers Checklist
If the gage/inspection affects quality, then conduct a
Gage R&R
NCR Confidential 94
DIMENSIONAL RESULTS
NCR Confidential 95
Dimensional Results
Objective or Purpose
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
NCR Confidential 96
NCR Dimensional Report (Critical)
Automatically
effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions.
Sample
Print zone or Nominal
spec note Value Tol + Tol - 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Cp Cpk Pass/Fail
Calculates Cpk!
#DIV/0! #DIV/0!
The number of critical data points required for part qualification is 35. These data points must be taken from a 35-piece sample. Five parts from a #DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to verify both critical and non-critical
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
dimensions. The supplier must clearly identify which of the 35 parts are being shipped. Critical dimensional results for the 5 parts being shipped must #DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
be entered below. Non-critical dimensional results must be entered into the "FAI Non-Critical Dimensions" worksheet. The supplier should make every #DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions.
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
List Gage R&R value: Name and ID of gage(s) used for measurement:
NCR Confidential 97
NCR Dimensional Report (Non-Critical)
The number of non-critical data points required for part qualification is 5. The non-critical data points
The number
must be of non-critical
taken from the same 35-piecedata points
sample required
as the critical for
data points. Fivepart
parts fromqualification
a production is 5. The non-critical data points
run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to
must beverify
taken fromandthe
both critical same
non-critical 35-piece
dimensions. sample
The supplier as identify
must clearly the critical
which of thedata
35 partspoints. Five parts from a production
run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to
are being shipped. Non-critical dimensional results for the 5 parts being shipped must be entered
below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The
verify both critical
supplier should makeandeverynon-critical
effort to ship 5 partsdimensions.
that represent both theThelow andsupplier
high ends of the must clearly identify which of the 35 parts
specifications for the non-critical dimensions.
are being shipped. Non-critical Cpk less than 1.33dimensional
will require action for results
improvement for the 5 parts being shipped must be entered
Nominal Automatically
below. CriticalValue dimensional results
1 Sample 2must
Sample 3 be entered into the
Cpk "FAIPass/FailCritical Dimensions" worksheet. The
Print zone or
spec note Tol + Tol - Sample Sample 4 Sample 5 Cp
PPAP Playbook!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0!
List Gage R&R value: Name and ID of gage(s) used for measurement:
NCR Confidential 98
Acceptance Criteria
NCR Confidential 99
NCR Dimensional Report Example
The number of non-critical data points required for part qualification is 5. The non-critical data points
must be taken from the same 35-piece sample as the critical data points. Five parts from a production
run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to
verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts
areNominal Value
being shipped. Non-critical dimensional results for the 5 parts being shippedCp
Tolerance & be
must Cpkentered
Sample Data Pass / Fail
Calculations
below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The
supplier should make every effort to ship 5 parts that represent both the low and high ends of the
specifications for the non-critical dimensions.
Cpk less than 1.33 will require action for improvement
Print zone or Nominal
spec note Value Tol + Tol - Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Cp Cpk Pass/Fail
35 0.50 0.50 34.86 34.78 34.88 34.86 34.82 4.167 2.833 Pass
76 0.50 0.50 75.96 76.08 75.92 75.93 76.09 2.017 2.001 Pass
3 0.50 0.50 3.175 3.18 3.156 3.168 3.178 17.118 11.250 Pass
3 0.50 0.50 3.18 3.156 3.178 3.175 3.18 16.406 10.703 Pass
3 0.50 0.50 3.18 3.175 3.174 3.18 3.156 16.836 11.011 Pass
3 0.50 0.50 3.156 3.18 3.173 3.175 3.18 16.862 11.034 Pass
Reviewers Checklist
Thirty-five critical data points & 5 non-critical data points are
required for part qualification
Critical and non-critical data points must be taken from the same 35-
piece sample
Five parts from a production run must be shipped to NCR for
verification of form, fit, and function
The same 5 parts will be used to verify both critical and non-critical
dimensions
Supplier must clearly identify which of the 35 parts are being shipped
Supplier should make every effort to ship 5 parts that represent both
the low and high ends of the specifications for non-critical dimensions
Capability must be greater than 1.67 for critical dimensions and
greater than 1.33 for non-critical dimensions
Type of
Material Spec. No./Date/Specification Supplier Test Results OK Not OK
Test
Type of Test Test description Parameters Tested Supplier Test Results OK Not OK
Submission Level
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
as an R on the PPAP
5. Process Flow Diagrams R R S * S
6. Process FMEA R R S * S
LSL USL
P rocess Data Within
LSL 24.5 Ov erall
What is It?
Target *
USL 25.5 P otential (Within) C apability
S ample M ean 25.1877 Cp 0.64
C P L 0.88
process capability.
O v erall C apability
Pp 0.63
PPL 0.86
PPU 0.39
P pk 0.39
C pm *
Objective or Purpose
24.6 24.8 25.0 25.2 25.4 25.6 25.8
O bserv ed P erformance
P P M < LS L 0.00
E xp.
PPM
Within P erformance
< LS L 4216.68
E xp. O v erall Performance
P PM < LS L 4866.91
To evaluate the performance of
P P M > U S L 110000.00
P P M Total 110000.00
PPM
PPM
> U S L 115840.63
Total 120057.30
P PM > U SL 120245.19
P PM Total 125112.10 your process as compared to
specification limits.
Process Capability Sixpack of Length
Xbar C har t C apability H istogr am
To determine if the production
process is likely to produce product
LSL USL
25.50 UCL=25.5380
S pecifications
Sample Mean
_ LS L 24.5
25.25 _
25.00
requirements
LCL=24.8375
1 3 5 7 9 11 13 15 17 19 24.6 24.8 25.0 25.2 25.4 25.6 25.8
1.0
When to Use It
_
R=0.607
0.5
2. To validate process
Last 2 0 Subgr oups C apability P lot
Within Within O v erall
25.5 S tDev 0.26108 S tDev 0.266035
improvements.
Values
Cp 0.64 Pp 0.63
O v erall
25.0 C pk 0.4 P pk 0.39
C pm *
24.5 S pecs
5 10 15 20
Sample
4. Collect data
limits important?
They may not represent what the customer truly
desires/needs.
15
Frequency
Is it what you would expect? 10
If not, investigate.
5
0
8 10 12 14 16 18 20 22
Mfg Hours
Bimodal Data
Histogram of Mfg Hours Histogram of Mfg Hours
Mean 19.9 20 Mean 20.1
25 StDev 1.71 StDev 18.8
N 10 N 10
Frequency
15
10
which type of Capability 10
Analysis applies. 5
5
0 0
16 18 20 22 24 -15 0 15 30 45 60 75
Mfg Hours Mfg Hours
Capability
Formula What it shows
Index
Relates short term (within subgroup) standard
(USL LSL) deviation to tolerance
Cp Sometimes called Entitlement, meaning it is the
Cp/Cpk
6*s short-term are used to
best the current process can do, if centered
estimate potential
Relates short term mean & short term (within
process capability
Min{(USL X), (X LSL)} subgroup) standard deviation to tolerance
Cpk Only tells you about the nearest spec limit; doesnt
3*sshort-term
tell anything about the other side
(USL LSL)
Relates long term (overall) standard deviation to
PP
6*slong-term tolerance
Pp/Ppk are used to
measure actual Relates mean & long term (overall) standard
Ppk process
Min{(USL X), (X performance
LSL)} deviation to tolerance
3*slong-term Only tells you about the nearest spec limit; doesnt
tell anything about the other side
Capable, Capable,
Centered Not Centered
Reviewers Checklist
Ensure that the results are acceptable, and that the
process is stable and capable of producing a quality
part
The name of the laboratory that performed the tests, the date(s)
of the tests, and the standards used to run the tests shall be
identified.
Part Name
Drawing Number
Date
A report completed by the supplier
Supplier Name Manufacturing Location Supplier Code containing appearance and color
criteria
Reason for Part Submission Warrant Re-Submission
Other
Special Sample
Submission
Pre Texture First Production Shipment Engineering Change
Appearance Evaluation
Pre-Texture Customer Representative
Supplier Sourcing and Texture Information
Evaluation signature and Date
Approved to Texture
To demonstrate that the part has
met the appearance requirements
Color Evaluation
Color
Color Master Master Material Material Metallic Part
When to Use It
Comments: Prior to tooling for production
Supplier Signature Phone No. Date Customer Representative Signature Date
IMPORTANT!
Typically only applies for parts with color, grain,
or surface appearance requirements
Administrative Section
Appearance Evaluation
Pre-Texture Customer Representative
Supplier Sourcing and Texture Information
Evaluation signature and Date
Approved to Texture
Master
Master
Material
Number
DateType
Material Source Color Shipping Suffix
Color Suffix
Enter
Enter
Identify
alphanumeric
the date
first
Identify
on
surface
which
firstfinish
surface
andand Color part number
Alphanumeric or
master numeric
thesubstrate
master
identification
was
substrate
(e.g.
approved
paint
suppliers
/ ABS) suffix or color number
color identification
Color Evaluation
Color
Color Master Master Material Material Metallic Part
Tristimulus Data Hue Value Chroma Gloss Shipping
Suffix Number Date Type Source Brilliance Disposition
Suffix
DL* Da* Db* DE CMC Red Yel Grn Blu Light Dark Gray CleanHigh Low High Low
Tristimulus Data
Part Disposition
List numerical (colorimeter) Hue, Value, Chroma, Gloss, and
To be determined by
data of submission part as Metallic Brilliance
NCR (approved or
compared
Comments: to the customer- Visual assessment by NCR
rejected)
authorized master
What is It?
Actual samples that reflect the parts
documented in the PPAP.
Objective or Purpose
Confirm cosmetic or functional
part approval.
When to Use It
Sample parts should be delivered
WITH the PPAP submission
Part description
Country of origin
C a p a b ilit y A n a ly s is N o rm a l D a ta D e fe ct o r
Yes V a r ia b le A tt r ib u t e
fo r N o rm a l D a ta D a ta ? Type? D e fe c tiv e
No D e fe c t
U s e M in it a b 's Is
" I n d iv id u a l re a s o n fo r D e t e r m in e r e a s o n s P o is s o n P r o c e s s
D is t r ib u tio n Yes N o n - N o r m a lit y No fo r C a p a b ilit y
I d e n t if ic a t io n " u n d e rsto o d ? N o n - N o r m a lity
fu n c tio n
U se N o n -N o rm a l C a p a b ilit y A n a ly s is
N o n -n o rm a l
C a p a b ilit y : fo r N o rm a l D a ta
D is t r ib u tio n Yes
S e le c t I d e n t if ie d ( u s in g B o x - C o x
I d e n t ifie d ?
D is t r ib u t io n T r a n s fo r m a t io n )
Yes
No
T ra n s fo r m th e Is
R a tio n a l d a t a u s in g B o x - tra n s fo rm e d
No No C o n ta ct y o u r M B B
S u b -g ro u p s ? Cox d a ta
T r a n s f o r m a t io n N o r m a l?
Yes No
C a p a b ilit y A n a ly s is
A p p ly C e n t r a l L im it R e s u lt in g
Yes fo r N o rm a l D a ta
T heorem d a t a N o r m a l?
( u s in g s u b g r o u p s )
Capability Normal
Capability - Normal
Capability Non-Normal
Distribution Identification
Activity
Using the data in a Minitab file Capability Example.MTW
determine the capability of the PO process in terms of the time
is required to process the POs.
Time to Process
one individual PO
Normal
StDev (Within):
Represents short term data.
18 24 30 36 42 48
StDev (Overall):E xp. Within P erformance
O bserv ed P erformance E xp. O v erall P erformance
Represents
% < LS L 7.50 long term
% < LS Ldata,
7.54 % < LS L 7.77
includes
% > U S L 10.00shift and%drift
> U S L 10.69 % > U S L 10.94
between
% Total subgroups.
17.50 % Total 18.23 % Total 18.70
LSL
Capability indices:
USL
Based on short
P rocess D ata Within
LS L 20.00000 term data. Ov erall
Target *
USL 40.00000 P otential (Within) C apability
S ample M ean 30.72100 Capability indices: Cp 0.45
S ample N 200 Based on long term C PL 0.48
C PU 0.41
SExp
tD ev (Within) 7.46329
Within Performance: data.
S tD ev (O v erall) 7.54439 C pk 0.41
Based on StDev(Within) C C pk 0.45
and represents short term O v erall C apability
process capability. Pp 0.44
Exp Overall Performance: PPL 0.47
Based on StDev (Overall) PPU 0.41
Observed Performance: and represents long term P pk 0.41
Represents the sample process capability. C pm *
data.
18 24 30 36 42 48
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
% < LS L 7.50 % < LS L 7.54 % < LS L 7.77
% > U S L 10.00 % > U S L 10.69 % > U S L 10.94
% Total 17.50 % Total 18.23 % Total 18.70
Exercise
Using the data (Time_2) in a Minitab file Capability Example.MTW
determine the capability of the PO process in terms of the time that is
required to process the POs.
Time to Process
one individual PO
Non-normal
Try Individual
Distribution
Identification
Overall Capability:
Process Capability of Time_2 Benchmark Z or
Calculations Based on Weibull Distribution Model Capability indices -
Sample Mean
based on long term data
Voice of the
LSL Customer USL
P rocess Data O v erall C apability
LS L 20.00000 Z.Bench 1.39
Target * Z.LS L 6.57
U SL 40.00000 Z.U S L 0.92
S ample M ean 31.04100 P pk 0.31
S ample N 200 Voice of the
E xp. O v erall P erformance
S hape 1.00817 Process P P M < LS L 0.0
S cale 6.06360
P P M > U S L 82696.6
Threshold 24.99750
P P M Total 82696.6
O bserv ed P erformance
P P M < LS L 0
P P M > U S L 75000
P P M Total 75000
Exp Overall
Performance:
Observed Performance: Represents long term
Represents the sample process capability
data
24 30 36 42 48 54
Activity
Using the data (Time_3 and Time 3 sub) in a Minitab file Capability
Example.MTW determine the capability of the PO process in terms of
the time is required to process the POs.
Average time
to process
five POs per
day
Time to
process one
individual PO
Non-normal
Try sub-grouping
the data
Caution!
Check sub-group data Time_3 sub for
normality. If the data is not normal then
this method cannot be used!
StDev (Within):
Represents short term data
StDev (Overall): 15 20 25 30 35 40 45 50
Represents long term data,
includes
O shift and
bserv ed P erformance drift
E xp. Within P erformance E xp. O v erall P erformance
P P M < LS L 85000.00 P P M < LS L 67997.38 P P M < LS L 89353.21
between subgroups
P P M > U S L 175000.00 P P M > U S L 123688.49 P P M > U S L 148388.88
P P M Total 260000.00 P P M Total 191685.87 P P M Total 237742.09
15 20 25 30 35 40 45 50
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
P P M < LS L 85000.00 PPM < LS L 67997.38 P P M < LS L 89353.21
P P M > U S L 175000.00 PPM > U S L 123688.49 P P M > U S L 148388.88
P P M Total 260000.00 PPM Total 191685.87 P P M Total 237742.09
Activity
Using the data (Time_4) in a Minitab file Capability Example.MTW
determine the capability of the PO process in terms of the time is
required to process the POs.
Time to Process
one individual PO
Non-normal
Try Box-Cox
transformation
Lower C L -0.071450
60 Upper C L 0.280506
StDev
40
Transformed Data
30
20 Lambda
Limit
Values
10
-1 0 1 2 3
Lambda
Original
Distribution LS L* U S L*
P rocess D ata transformed data Calculated
Within
LS L 20.00000 Lambda
O v erall
Target *
USL 40.00000 P otential (Within) C apability
S ample M ean 27.73850 Cp 0.15
S ample N 200 Transformed C P L 0.01
S tDev (Within) 20.18069 Voice ofCC Ppk U 0.28
the 0.01
S tDev (O v erall) 23.20715
Customer C C pk 0.15
A fter Transformation
O v erall C apability
LS L* 1.49272
Target* * Pp 0.14
Original P P L 0.01
U S L* 1.63770
Sample Data Transformed
P P U 0.27
S ample M ean* 1.49973
S tDev (Within)* 0.16316
VoiceP pk
of the
0.01
S tDev (O v erall)* 0.17276 Process
C pm *
Arepresents
fter Transformation short
term C C pk 0.15
Exp Overall
LS L*process 1.49272
capability. O v erall C apability
Performance: Based on
Target* * Pp 0.14
Observed StDev (Overall) and PPL 0.01
U S L* 1.63770
Performance:
S ample M ean* 1.49973 represents long term PPU 0.27
process capability. P pk 0.01
Represents the
S tDev (Within)* 0.16316
S tDev (O v erall)* 0.17276 C pm *
sample data