WORKBOOK V4.0
Copyright 2006 March Quality Services
Part Name
Part Number
Engineering Change Level
Engineering Change Level Date
NAME
NUMBER
ECL
ECL DATE
Supplier Name
Supplier Code
Street Address
City
State
Zip
Phone Number
SUPPLIER
CODE
ADDRESS
CITY
STATE
ZIP
555-555-5555
Customer Name
Division
Application
#NAME?
DIVISION
APPLICATION
File Name
FILE.XLS
Revision Level:
ECL
NAME
SUPPLIER
Date on Print:
ECL DATE
Part Number:
Part Name:
Supplier Name:
Date Received:
ITEM NAME
1) Design Record
Fail
N/A
Pass
ITEM NAME
Fail
Is it ballooned?
6) Process FMEA
Correct part number/drawing number/revision level
7) Control Plan
Correct part number/drawing number/revision level.
All processes must be included and each process must
include the appropriate controls being used.
18) Warrant
9) Dimensional Results
Correct part number/drawing number/revision level.
Show 6 piece layout data results (not a range), or 1 per cavity
(whichever is greater).
Numbered per ballooned print.
All dimensions within tolerances.
Misc.
The original completed Excel PPAP Forms per the Viking
Format must be emailed. Supporting documents can be
scanned and emailed also. A hard copy and layout samples
are to be shipped to Viking.
For any outside processing (ex. Plating, coating, heat
treatment, etc.) a PPAP must be requested from outside
processor and Submitted.
The completed PPAP package must be reviewed in its entirety
by another Quality Engineer, Project Engineer or Manager
before submitting to Viking.
Notes:
Supplier Signoff:
Signature
Date
Signature
Date
N/A
DATE:
ECL:
PREPARED BY:
OPERATION
DESCRIPTION
ITEM #
STORE
MOVE
INSPECT
STEP
FABRICATION
NAME
PRODUCT AND
PROCESS
CHARACTERISTICS
Page 3 of 15
ECL
ITEM #
PART NUMBER:
PART DESCRIPTION:
CONTROL
METHODS
Print #
NUMBER
Item:
Rev.
ECL
NAME
Model Year(s)/Vehicle(s)
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
Process Responsibility
APPLICATION
FMEA Number:
SUPPLIER
Prepared by:
Key Date
Date (Orig.)
Core Team:
Process
Function/
Requirements
FILE.XLS
Date (Rev.)
Potential
Failure
Mode
Potential
Effect(s)
of Failure
S
e
v
C
l
a
s
s
Potential
Causes(s)/
Mechanism(s)
of Failure
O
c
c
u
r
Current
Process
Controls
Prevention
Page 4 of 15
Current
Process
Controls
Detection
D
e
t
e
c
R.
P.
N.
Recommended
Action(s)
Responsibility
& Target
Completion
Date
Action Results
Actions
Taken
S
e
v
O
c
c
D
e
t
R.
P.
N.
CONTROL PLAN
Prototype
Control Plan Number
Pre-Launch
Production
Key Contact/Phone
Date (Orig.)
FILE.XLS
555-555-5555
NUMBER
Date (Rev.)
1/1/1996
1/1/1996
Core Team
Supplier/Plant Approval/Date
ECL
Part Name/Description
NAME
Supplier/Plant
SUPPLIER
PART/
PROCESS NAME/
PROCES
OPERATION
S
DESCRIPTION
NUMBER
Supplier Code
CODE
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
CHARACTERISTICS
NO.
PRODUCT
PROCESS
METHODS
SPECIA
L
PRODUCT/PROCESS EVALUATION/
SAMPLE
CHAR.
SPECIFICATION/ MEASUREMENT
CLASS
SIZE
FREQ.
TOLERANCE
TECHNIQUE
Page 5 of 15
CONTROL
METHOD
REACTION
PLAN
Page 6 of 15 Pages
SUPPLIER
CODE
NUMBER
NAME
PART NUMBER:
PART NAME:
INSPECTION FACILITY:
ECL
ITEM
DIMENSION / SPECIFICATION
SPECIFICATION /
LIMITS
TEST
DATE
#1
#2
#3
#4
#5
OK
#6
March CFG-1003
2006
TITLE
DATE
NOT
OK
Page 7 of 15 Pages
SUPPLIER
CODE
PART NUMBER:
PART NAME:
INSPECTION FACILITY:
NUMBER
NAME
ECL
ITEM
DIMENSION / SPECIFICATION
March CFG-1003
2006
SPECIFICATION /
LIMITS
TEST
DATE
OK
NOT
OK
Page of Pages
SUPPLIER
CODE
NUMBER
NAME
PART NUMBER:
PART NAME:
MATERIAL SUPPLIER:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
SPECIFICATION /
LIMITS
ECL
TEST
DATE
QTY.
TESTED
OK
March CFG-1004
2006
TITLE
DATE
NOT
OK
Page of Pages
SUPPLIER
CODE
PART NUMBER:
PART NAME:
NUMBER
NAME
MATERIAL SUPPLIER:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
March CFG-1004
2006
SPECIFICATION /
LIMITS
ECL
TEST
DATE
QTY.
TESTED
OK
NOT
OK
Page 10 of 15 Pages
SUPPLIER
CODE
NUMBER
NAME
PART NUMBER:
PART NAME:
NAME of LABORATORY:
ECL
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
SPECIFICATION /
LIMITS
TEST
DATE
QTY.
TESTED
OK
March CFG-1005
2006
TITLE
DATE
NOT
OK
Page 11 of 15 Pages
SUPPLIER
CODE
PART NUMBER:
PART NAME:
NUMBER
NAME
NAME of LABORATORY:
ECL
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
March CFG-1005
2006
SPECIFICATION /
LIMITS
TEST
DATE
QTY.
TESTED
OK
NOT
OK
Gage Name
Appraiser A
Gage Number
Appraiser B
Gage Type
Appraiser C
NUMBER
Part Name
NAME
Characteristic
Specification
Lower Upper
Characteristic Classification
Trials
Parts
APPRAISER/
TRIAL #
1
2.
3.
4.
AVE
5.
6. B
7.
8.
9.
AVE
10.
11. C
12.
13.
14.
AVE
15.
Date Performed
PART
1
1. A
Appraisers
AVERAGE
6
10
xa=
ra=
xb=
rb=
x c=
rc=
X=
16. PART
Rp=
AVERAGE
17.
18.
19.
* UCLR =
R x D4 =
R=
xDIFF=
UCLR=
* 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.
Notes:
Gage Name
Appraiser A
Gage Number
Appraiser B
Characteristic
Gage Type
Appraiser C
Characteristic Classification
Trials
NUMBER
Part Name
NAME
Parts
Appraisers
Date Performed
% Tolerance (Tol)
R x K1
Trials
K1
% EV
0.8865
0.5907
100 (EV/Tol)
% AV
n = parts
Appraisers
K2
0.7087
0.5236
r = trials
K3
0.7087
0.5236
0.4464
0.4032
0.3745
0.3534
0.3378
{(EV2 + AV2)}1/2
RP x K3
Tolerance (Tol)
Tol
% GRR
Parts
Upper - Lower / 6
0.3247
( Upper - Lower ) / 6
10
0.3145
% PV
ndc
100 (AV/Tol)
100 (GRR/Tol)
100 (PV/Tol)
1.41(PV/GRR)
=
=
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
Part Name
NUMBER
ECL
Dated
ECL DATE
Dated
Yes
No
Weight (kg)
SUPPLIER
Dated
CODE
###
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
n/a
Yes
No
n/a
Engineering Change(s)
Correction of Discrepancy
dimensional measurements
material and functional tests
appearance criteriastatistical process package
(If "NO" - Explanation Required)
Yes
NO
I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all
Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the 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.
EXPLANATION/COMMENTS:
Yes
No
n/a
Date
Print Name
Phone No.
Title
555-555-5555
Fax No.
E-mail
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Approved
Rejected
Other
Customer Signature
Print Name
March
2006
CFG-1001
Date
Customer Tracking Number (optional)
CUSTOMER LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
ACTIVE # IN DOCUMENT
GM
Ford Motor Company
DaimlerChrysler
Viking Products
SEVERITY SCALE
10 Hazardous - w/o warning
9 Hazardous - w/ warning
8 Very High
7 High
6 Moderate
5 Low
4 Very Low
3 Minor
2 Very Minor
1 None
OCCURENCE SCALE
10 >100 Per 1,000
9 50 Per 1,000
8 20 per 1,000
7 10 Per 1,000
6 5 Per 1,000
5 2 Per 1,000
4 1 Per 1,000
3 0.5 per 1,000
2 0.1 Per 1,000
1 <0.01 Per 1,000
DETECTION SCALE
10 Absolute Impossible
9 Very Remote
8 Remote
7 Very Low
6 Low
5 Moderate
4 Moderately High
3 High
2 Almost Certain
1 Certain