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Part Number Customer Part No Part Name Drawing Number Rev Level Rev Date Purchase Order Number Part Weight (kg) Application Supplier Name Supplier Street Address City State Country Zip Supplier Code Supplier Representative Title E-Mail Supplier Ph Number Fax Number Customer Name Division Buyer Buyer Code Lab/Inspection. Facility Control Plan# FMEA# Approval Date

1/1/1900

Supplier Name

USA

1/1/1900

PPAP Package
Supplier Name
Organization Name

0
Code Customer Name

0 0
Customer Contact/Code

0
Street Address

0
City State

0
Zip Application

part picture here.

?
Part Number

description here
Part Name

current rev date here 0


Revision Date Revision level

Part Submission Warrant


Part Name 0 Part Number

0 0 1/0/1900

Rev. Dated Dated

0 1/1/1900 0.00

Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing Number Checking Aid Number

Yes

No

Engineering Drawing Change Level

Purchase Order No. Engineering Change Level

Weight (kg) Dated

ORGANIZATION MANUFACTURING INFORMATION

CUSTOMER SUBMITTAL INFORMATION

0
Organization Name and Code

0
Customer Name/Division

0 0

0
Street Address

0
Customer Contact /Code

0
City Note:

0
State

0
Zip

0
APPLICATION

Does this part contain any restricted or reportable substances? Are plastic parts identified with appropriate ISO marking codes?

Yes
Yes

No
No

REASON FOR SUBMISSION (Check at least one) Initial submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one) 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 4 - Warrant and other requirements as defined by customer.
1
(Check)

Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part Processing Parts produced at Additional Location Other - please specify

10

11

12

13

14

15

16

17

18

19

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. DECLARATION I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable customer drawings and specifications and are made form specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence of such compliance is on file and available for review. EXPLANATION/COMMENTS:

List Molds/Cavities/Production Processes Organization Authorized Signature Print Name 0 Title 0 Phone No. E-mail 0 Fax 0 Date

FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition: Customer Signature Print Name

Approved Interim Approval

Rejected
Date

Comments:

March 2006 THE-1001

PROCESS FLOW DIAGRAM


PART NUMBER: 0
0

DATE: ECL: 0 PREPARED BY: 0

1/1/1900

PART DESCRIPTION:

Operation

INSPECT

STORE

MOVE

STEP 1

OPERATION DESCRIPTION Process steps here Process steps here

PRODUCT AND PROCESS CHARACTERISTICS .28" what is important characteristics at this step what is important characteristics at this step what is important characteristics at this step what is important characteristics at this step what is important characteristics at this step what is important characteristics at this step is important what characteristics at this step what is important characteristics at this step what is important characteristics at this step is important what characteristics at this step is important what characteristics at this step what is important characteristics at this step what is important characteristics at this step is important what characteristics at this step is important what characteristics at this step what is important characteristics at this

ITEM #

ITEM # 1 2 3 4 5 6 7 8 9

CONTROL METHODS Calipers how is it checked or controlled. how is it checked or controlled. how is it checked or controlled. how is it checked or controlled. how is it checked or controlled. how is it checked or controlled. how is it checked or controlled. how is it checked or controlled.

2 Process steps here 3 Process steps here 4 Process steps here 5 Process steps here 6 Process steps here 7 Process steps here 8 Process steps here 9 Process steps here 10 Process steps here 11 Process steps here 12 Process steps here 13 Process steps here 14 Process steps here 15 Process steps here 16 Process steps here 17

6 7

9 10 11

12 13 14 15 16 17

how is it checked or 10 controlled. how is it checked or 11 controlled. how is it checked or controlled. 12 how is it checked or 13 controlled. how is it checked or 14 controlled. how is it checked or 15 controlled. how is it checked or 16 controlled. how is it checked or 17 controlled.

PROCESS FLOW DIAGRAM


Process steps here 18 Process steps here 19 Process steps here 20 Process steps here 21 Process steps here 22 Process steps here 23 Process steps here 24 Process steps here 25
TRO-QUA-F-001

what is important 18 characteristics at this what is important 17 characteristics at this step what is important characteristics at this 18 step what is important characteristics at this 19 step what is important 19 characteristics at this step what is important 20 characteristics at this what is important characteristics at this 20 step what is important 21 characteristics at this step 4/26/2006

how is it checked or 18 controlled. how is it checked or 17 controlled. how is it checked or controlled. 18 how is it checked or controlled. 19 how is it checked or 19 controlled. how is it checked or 20 controlled. how is it checked or controlled. 20 how is it checked or 21 controlled.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


Print # 0 Item:
0

Rev. 0 Process Responsibility: 0 Key Date


Design FMEA is attached

FMEA Number: 0 Supplier Name 1/1/1900 Prepared by: 0 Date (Orig.) Date (Rev.)
O c c u r Current Process Controls Prevention Current Process Controls Detection D e t e c

Model Year(s)/Vehicle(s): Team:

1/1/1900

Step

Process Function/Requirements Process steps here

Potential Effect(s) of Failure Potential Failure Mode

S e v

C l a s s

Potential Cause(s)/ Mechanism(s) of Failure

R. P. N.

Recommended Actions

Responsibility & Target Date

Actions Taken

Action Results S O e c v c

D e t

R. P. N.

1 Process steps here

2 Process steps here

3 Process steps here 4 Process steps here 5 Process steps here 6 Process steps here

7 Process steps here

8 Process steps here 9 Process steps here 10 Process steps here 11 Process steps here 12 Process steps here 13 Process steps here 14

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)


Step 14 Process steps here 15 Process steps here Process Function/RequireProcess steps here ments Potential Effect(s) of Failure Potential Failure Mode S e v C l a s s Potential Cause(s)/ Mechanism(s) of Failure O c c u r Current Process Controls Prevention Current Process Controls Detection D e t e c R. P. N. Recommended Actions Responsibility & Target Date Actions Taken Action Results S O e c v c D e t R. P. N.

16 Process steps here 17 Process steps here

18 Process steps here 19 Process steps here

20 Process steps here 21 Process steps here

22 Process steps here 23 Process steps here

24 Process steps here 25

CONTROL PLAN
Prototype
Control Plan Number

Pre-Launch

Production
Key Contact/Phone

Engineering Change Documents are attached


Date (Orig.) Date (Rev.)

0
Part Number/Latest Change Level

0
Core Team

1/1/1900
Customer Engineering Approval/Date (If Req'd.) Customer Quality Approval/Date (If Req'd.)

0
Part Name/Description

1/1/1900

0
Supplier Approval Date 0

1/1/1900
Other Approval/Date (If Req'd.) CHARACTERISTICS Other Approval/Date (If Req'd.)

Supplier/Plant Supplier Name PART/ PROCESS NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PROCESS NAME/ OPERATION DESCRIPTION Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here Process steps here

Supplier Code

0
MACHINE, DEVICE, JIG,TOOLS, FOR MFG. METHODS SPECIAL CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. TOLERANCE TECHNIQUE REACTION PLAN

NO.

PRODUCT

CONTROL METHOD

16 17 18

Process steps here Process steps here Process steps here

19 20 21

Process steps here Process steps here Process steps here

CONTROL PLAN
22 23 24 25 Process steps here Process steps here Process steps here Process steps here
26-Apr-06

TRO-QUA-F-001

PRODUCTION PART APPROVAL

DIMENSIONAL RESULTS
Organization: Supplier/Vendor Code: Inspection Facility:

Supplier Name 0
0

Part Number: Part Name:

0
0.00

Design Record Change Level: Engineering Change Documents:

Item

Dimension/Specification Part Number Description

Test Date

Qty. Tested

Organization Measurement Results (Data)

Ok

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
March 2006 CFG-1003 Blanket statements of conformance are unacceptable for any test results. SIGNATURE TITLE DATE

PRODUCTION PART APPROVAL

DIMENSIONAL RESULTS

Not Ok

able for any test results. DATE

PRODUCTION PART APPROVAL

PERFORMANCE TEST RESULTS


Organization:

Supplier Name

Part Number: Part Name:

0
0

Supplier/Vendor Code: 0 Name of Laboratory:

Design Record Level Change: Engineering Change Documents:

*Customer Specified Supplier/Vendor Code:


* If source approval is req'd, include the Supplier (Source) & Customer assigned code.

Test Specification / Rev / Date

Specification / Limits

Test Date

Qty. Tested

Supplier Test Results (Data) / Test Conditions

Ok

Not Ok

March 2006

CFG-1005

Blanket statements of conformance are unacceptable for any test results. SIGNATURE TITLE DATE

APPEARANCE APPROVAL REPORT


PART NUMBER PART NAME SUPPLIER NAME REASON FOR SUBMISSION 0 0 Supplier Name PART SUBMISSION WARRANT PRE TEXTURE DRAWING NUMBER BUYER CODE MANUFACTURING LOCATION SPECIAL SAMPLE FIRST PRODUCTION SHIPMENT 0 APPLICATION (VEHICLES) E/C LEVEL 0

0 0

DATE SUPPLIER CODE

RE-SUBMISSION ENGINEERING CHANGE

OTHER

APPEARANCE EVALUATION
Organization Sourcing & Texture Information
Pre-Texture Evaluation Authorized Customer Representative Signature & Date

Correct & Proceed

Correct & Resubmit

Approved to Texture

COLOR EVALUATION
COLOR SUFFIX DL* TRISTIMULUS DATA Da* Db* DE* CMC MASTER NUMBER MASTER DATE MATERIAL MATERIAL TYPE SOURCE
RED

HUE

VALUE

CHROMA

GLOSS

COLOR METALLIC PART SHIPPING BRILLIANCE DISPOSITION SUFFIX


HIGH LOW

YEL

GRN

BLU

LIGHT

DARK

GRAY

CLEAN

HIGH

LOW

COMMENTS

SUPPLIER SIGNATURE

Supplier Name

PHONE NUMBER

DATE

AUTHORIZED CUSTOMER REPRESENTATIVE SIGNATURE

DATE

FMEA LISTS
Third Edition

Table 6, Page 43: PFMEA Severity Evaluat


Criteria: Severity of Effect This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the two severities.

SEVERITY SCALE

10 Hazardous - w/o warning

9 Hazardous - w/ warning

(CUSTOMER EFFECT) Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning. Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.

8 Very High

Vehicle/item inoperabe (loss of primary function).

7 High

Vehicle/Item operable but at a reduced level of performance. Customer very dissatisfied

6 Moderate

5 Low

Vehicle/Item operable but Comfort/Convenience item(s) inoperable. Customer dissatisfied. Vehicle/Item operable but Comfort/Convenience item(s) operable at a reduced level of performance. Fit and Finish/Squeak and Rattle item does not conform. Defect noticed by most customers (greater than 75%). Fit and Finish/Squeak and Rattle item does not conform. Defect noticed by 50% of customers.

4 Very Low

3 Minor

2 Very Minor 1 None OCCURRENCE SCALE 10 >/= 100/1000 pieces - Very High 9 50/1000 pieces - Very High 8 20/1000 pieces - High 7 10/1000 pieces - High 6 5/1000 pieces - Moderate 5 2/1000 pieces - Moderate 4 1/1000 pieces - Moderate 3 .5/1000 pieces - Low 2 .1/1000 pieces - Low 1 </= .01/1000 pieces - Remote

Fit and Finish/Squeak and Rattle item does not conform. Defect noticed by discriminating customers (less than 25%). No discernible effect.

Persistent Failures Persistent Failures Frequent Failures Frequent Failures Occasional Failures Occasional Failures Occasional Failures Relatively Few Failures Relatively Few Failures Failure is Unlikely

DETECTION SCALE 10 Almost Impossible 9 Very Remote 8 Remote 7 Very Low 6 Low

Table 8, Pg. 53: PFMEA Detection Evaluation Criteria Absolute certainty of non-detection. Controls will probably not detect. Controls have poor chance of detection. Controls have poor chance of detection. Controls may detect.

5 Moderate

Controls may detect. Controls have a good chance to detect.

4 Moderately High

3 High

Controls have a good chance to detect.

2 Very High

Controls almost certain to detect.

1 Very High
TRO-QUA-F-001 26-Apr-06

Controls certain to detect.

PFMEA Severity Evaluation Criteria


Criteria: Severity of Effect This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the two severities. (MANUFACTURING/ ASSEMBLY EFFECT)

Or may endanger operator (machine or assembly) without warning.

Or may endanger operator (machine or assembly) with warning. Or 100% of product may have to be scrapped, or vehicle/item repaired in repair department with a repair time greater than one hour. Or product may have to be sorted and a portion (less than 100%) scrapped, or vehicle/item repaired in repair department with a repair time between a half-hour and an hour. Or a portion (less than 100%) of the product may have to be scrapped with no sorting, or vehicle/item repaired in repair department with a repair time less than a half-hour. Or 100%of product may have to be reworked, or vehicle/item repaired offline but does not go to repair department. Or the product may have to be sorted, with no scrap, and a portion (less than 100%) reworked. Or a portion (less than 100%) of the product may have to be reworked, with no scrap, on-line but out-ofstation.

Or a portion (less than 100%) of the product may have to be reworked, with no scrap, on-line but out-ofstation. Or slight inconvenience to operation or operator, or no effect.

PFMEA Detection Evaluation Criteria Inspection Types Manual Inspection Manual Inspection Manual Inspection Manual Inspection Gauging and Manual Inspection

Suggested Range of Detection Methods Cannot detect or is not checked. Control is achieved with in direct or random checks only. Control is achieved with visual inspection only. Control is achieved with double visual inspection only. Control is achieved with charting methods, such as SPC (Statistical Process Control). Control is based on variable gauging after parts have left the station, or G0/No Go gauging performed on 100% of the parts after parts have left the station. Error detection in subsequent operations, OR gauging performed on setup and first-piece check (for set-up causes only). Error detection in-station, or error detection in subsequent operations by multiple layers of acceptance: supply, select, install, verify. Cannot accept discrepant part. Error detection in-station (automatic gauging with automatic stop feature). Cannot pass discrepant part. Discrepant parts cannot be made because item has been error-proofed by process/product design.

Gauging

Error-proofed and gauging

Error-proofed and gauging

Error-proofed and gauging

Error-proofed

Retention/Submission Requirements Table (Normative)


[NOTE: table 4.2 lists submission and retention requirements. Mandatory and applicable requirements for a PPAP record are defined in the PPAP manual and by the customer.]

Requirements 1 Design Record for proprietary components/details for all other components/details 2 Engineering Change Documents, if any 3 Customer Engineering approval, if required 4 Design FMEA 5 Process Flow Diagrams 6 Process FMEA 7 Control Plan 8 Measurement System Analysis Studies 9 Dimensional Results 10 Material, Performance Test Results 11 Initial Process Studies 12 Qualified Laboratory Documentation 13 Appearance Approval Report (AAR), if applicable 14 Sample Product 15 Master Sample 16 Checking Aids 17 Records of Compliance with Customer-Specific requirements 18 Part Submission Warrant (PSW) 19 Bulk Material Checklist

Level 1 Level 2 Level 3 Level 4 Level 5 R S S * R R R R * R R S S * R R S S * R R R S * R R R S * R R R S * R R R S * R R R S * R R R S * R R S S * R R S S * R R R S * R R S S * R S S S * R R S S * R R R R * R R R S * R R R S * R S S S S R S S S S R

S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations. R = The organization shall retain at appropriate locations and make available to the customer upon request. * = The organization shall retain at appropriate locations and submit to the customer upon request.