APQP Forms

Our Name: Adams Thermal Systems

Customer Name: Behr

Part Name:Part Number:

Rev. Level:Rev. Date:

Product Program:

Key Production Date:

LAST UPDATE

PPAPCustomer Name: Behr

Part Name: Part Number: Rev. Level:

Product Program:

PSO Submission Date:

PP

AP

0

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:

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: Pa

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e: Beh

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Part Submission WarrantPart Name 0 Part Number 0

Safety and/orGovernment Regulation Yes No Engineering Drawing Change Level 0 Dated 0

Additional Engineering Changes Dated

Shown on Drawing No. 0 Purchase Order No. Weight (kg)

Checking Aid No. Engineering Change Level Dated 0

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Adams Thermal Systems Dimensional Materials/Functional Appearance

Supplier Name & Supplier Code Supplier CodeCustomer Name/Division Behr

Street Address Buyer/Buyer Code

MI Application 0

City State Zip

Note: Does this part contain any restricted or reportable substances. Yes No

Are plastic parts identified with appropriate ISO marking codes Yes No

REASON FOR SUBMISSION

Initial Submission Change to Optional Construction or Material

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 Additional Location

Tooling Inactive > than 1 year Other - please specify

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.

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS

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

These results meet all drawing and specification requirements: (if "No" - Explanation Required)

Mold / Cavity / Production Process

DECLARATION

I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable

Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were

produced at the production rate of / 8 hours. I have noted any deviations from this declaration below.

EXPLANATION/COMMENTS:

Print Name: Title: Phone No: Fax No.

Supplier Authorized Signature Date

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition: Approved Rejected Part Functional Approval: Approved

Other Waived

Customer Name Customer Signature Date

July The original copy of this document shall remain at the suppliers location Optional: customer tracking

1999 while the part is active (see Glossary). number: # _______________CFG-1001CFG-1001

NoYes

Daimler Chrysler

Production Part Approval ___Dimensional Results

Page 1 of 4

SUPPLIER PART NUMBER

Adams Thermal Systems 0NAME OF INSPECTION FACILITY PART NAME

0NOT

ITEM DIMENSION / SPECIFICATION SUPPLIER TEST RESULTS OK OK

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

MAY CFG-1003 SIGNATURE TITLE DATE

1995

GMDaimler Chrysler


Page 2 of 4



0NOT


23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44


1995

GMDaimler Chrysler


Page 3 of 4



0NOT


45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66


1995

GMDaimler Chrysler


Page 4 of 4



0NOT


67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88


1995

GMDaimler Chrysler

Production Part Approval ___Material Test Results


Adams Thermal Systems 0NAME OF LABORATORY PART NAME

0TYPE OF NOT

TEST MATERIAL SPEC. NO. / DATE / SPECIFICATION SUPPLIER TEST RESULTS OK OK


1995 QUALITY MGR.

Page 1 of 1 Pages

GMDaimler Chrysler

PROCESS FLOW DIAGRAM

Flow04/08/2023 of 21

PART NUMBER: 0 MFG. ENG.:

PART NAME: 0 QUAL. ENG.:

CUSTOMER: Behr PLANT MGR.:

E.C.L.: 0

t l n

Ste

p

Ope

ratio

n

Mov

e

Sto

re

Ins

pect Operation Description

10 n Incoming Inspection

20

Store Material

30 l Move To Press

40 t Load on Uncioler

50 t Straighten

60 t Oil

70 t Form

80

n Inspect

90 t Pack

100 l Move to Shipping

110

Store in Shipping

120 l Ship

OPERATOR KEY

TD TRUCK DRIVER MO MACHINE / PRESS OPERATOR

MH MATERIAL HANDLER / HI-LO AO ASSEMBLY OPERATOR

ST STOCK / STORAGE RC RECEIVING CLERK

PT PROCESS / PRESS TECHNICIAN QA QUALITY INSPECTOR

REV. DATE: 11/18/04

Tool / Gage / Fixture / Location / Operator Key Product / Process Characteristics

FAILURE MODES EFFECT ANALYSIS

KB Stamping FMEA 11/1/04 of 21

PART NAME AND NUMBER: / PROCESS RESPONSIBILITY: FMEA DATE (ORIG.): 1/4/2005

Rev Level/Date KEY PRODUCTION DATE: FMEA DATE (REV.):

CORE TEAM MEMBERS: MODEL YEAR(S) / VEHICLE(S): PREPARED BY:

PART NAME: MODEL VEHICLE:

Current Process Controls Action Results

Prevention Detection

10 4 1 Check at receiving 1 4

Incorrect alloy 8 1 1 8

40 4 1 Check at Press 1 4

Clad on Wrong Side 8 1 10 80

50 Straighten Die Feed Problems 2 Not Set Correctly 2 2 8

60 Oil Leaks on Assembly 5 2 Visual inspection 8 80

Parts stick in die 3 4 Die problems 1 12

Burrs on part 3 4 Visual inspection 8 96

Oily Parts 6 Oiler set too high 2 Visual inspection 8 96

70 Form 6 Incorrect Progression 2 Part Layout 2 24

Die Shut Ht. Incorrect 6 2 Part Layout 2 24

Die Worn/Broken 6 Die/Worn Broken 2 Die PM System Part Layout/ 2 24

90 Pack No Build at Behr 8 3 8 192

8 3 8 192

STEP

ProcessFunction

PotentialFailureMode

PotentialEffect(s) of

Failure

SEV

CLASS

PotentialCause(s)/

Mechanism(s)of Failure

OCCUR

DETECT

RPN

RecommendedAction(s)

Responsibility& Target

Completion DateActionsTaken

SEV

OCC

DET

RPN

Incoming Inspection

Incorrect material - Dimensional

Non Conforming Product

Wrong Material Shipped to ATS

Braze Problems at Behr


Check Material Certification

Load Coil on Uncoiler

Incorrect material - Dimensional

Non Conforming Product



Material Clad on Wrong Side

Material not Straight into dieCrakcing/ Thinning of material

Oiler not working/ empty

Non conforming Product- Dimensional





Progression set incorrectly

Incorrect Part Width/ Collar Ht.Incorrect Collar Ht and Part Flatness

Die shut Ht. set incorrectly


Wrong Part # on Container

Incorrect label installed

Wrong "Born on Date"


Incorrect Date samped on Container

KB Stamping8110 Graphic Dr.-Belmont, MI. 49306

Phone:(616) 866-5917 Fax: (616) 866-5918

KB Stamping Production Control Plan 11/1/04 of 21

KB STAMPINGS REP. CUSTOMER REP. (IF APPLICABLE)

PART NUMBER/E.C.L.: PLANT MGR.: _____________________ DATE: _____________ Q.A. REP.: ___________________________ DATE: _____________

/

MFG. ENG.: _______________________ DATE: _____________ ENG. REP.: __________________________ DATE: _____________

PART NAME:

0 Q.A. MGR.: _______________________ DATE: _____________ MGMT. REP.: _________________________ DATE: _____________

Part Name Model Vehicle KB NUMBER: Characteristics Methods

Reaction Plan ACTUAL MEASUREMENTNo. Product Process

SampleControl Method

Size Freq.

Rec

Insp

SUPPLIER LOCATION: FIRST ISSUED:

SUPPLIER PHONE: REVISED:

SUPPLIER CODE: SUPERCEDES:

PROTOTYPE

PRE-LAUNCH

PRODUCTION

Part/ProcessNumber

Process Name/

OperationDescription

Machine, Device,Jig, DiesFor Mfg.

SpecialChar.Class

Product/ProcessSpecification/

Tolerance

EvaluationMeasurement

Technique

PROCESS CONTROL PLAN


Phone:(616) 866-5917 Fax: (616) 866-5918





Size Freq.

Part/ProcessNumber

Process Name/



SpecialChar.Class


Tolerance


Technique

10

20

30


Phone:(616) 866-5917 Fax: (616) 866-5918





Size Freq.

Part/ProcessNumber

Process Name/



SpecialChar.Class


Tolerance


Technique

Production Inspection Sheet

KB Stamping Production Inspection Sheet 01/27/03 of 21

Check 1st piece at set-up or start of day and record data. Check 1 part at the start of each coil & 1 part per bin Check Last piece from Production Run, Record Data, Attach last & 1st piece part to fixture Shut down and notify Management of any non conformancePrint Rev.: Rev Date: Customer:

0 0 BehrPart Number: Part Name Lot No.: Date:

0 0

Sample No. 1 Sample No. 2 Sample No. 3 Sample No. 4 Sample No. 5Print Specification & Characteristic

OPERATION INSTRUCTIONS

Form Revision: 10/04/04 of 21

PART NAME: 0 OPERATION(S): 10 Progressive Complete ISSUED BY: DATE:

PART NUMBER: 0 APPROVED BY: DATE:

KB JOB NUMBER: 0

WORK STATION OPERATION METHOD PACKAGING INSTRUCTIONS

OPERATOR

1)

2)

3)

4)

5) Place packaging picture here

6)

7)

QUALITY CRITERIA GAGE INSTRUCTIONS

7) USE FEELER GAGES

TO VERIFY PROPER

FORM / FORM

LOCATION AS SHOWN

ON FIXTURE.

Place part picture here

1)8) USE YELLOW

SCRIBE LINES TO2) VERIFY PROPER TRIM

LOCATIONS.

3)

4) CLAMP PART ONTO FIXTURE

5)

6)

FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS.

RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.

VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE.

WHEN LOADING MATERIAL INTO DIE, ASSURE THAT IT IS ALIGNED "PARALLEL" TO THE DIE.

WHEN THE MATERIAL IS COMPLETELY LOADED, PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT.

WHEN FIRST PIECE IS APPROVED, RUN PRESS IN FULL AUTOMATIC MODE.

MONITOR SCRAP REMOVAL SO THAT IT DOESN'T AFFECT DIE.

WHEN THE CONTAINER IS FULLACCORDING TO PACKAGING INSTRUCTIONS.

APPLY COMPLETED PRODUCT INVENTORY LABEL TO SKID.

PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.

PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.

PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.

INSERT 11.80MM STAB PIN INTO CENTER HOLE TO VERIFY POSITION

REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10 STAB PIN INTO EACH SLOT TO VERIFY POSITION

OP. 10PRESS

DIE

FINISH GOODS SKID

GAGETABLE

FIRST PIECE AND IN

PROCESS INSPECTION

CONVEYOR TO CARDBOARD BOX

5.

6.

7.

8.

BOX

DIE SETUP SHEET


KB JOB NUMBER: 0 ISSUED BY: DATE:

PART NAME: 0 APPROVED BY: DATE:

CUSTOMER: Behr

SUBJECT REQUIREMENT

PRESS SIZE STOCK (MATERIAL) SIZECOUNTER BALANCE PRESSURESHUT HEIGHTFEED ROLLER PRESSUREMATERIAL FEED DISTANCEMATERIAL FEED RATESTRAIGHTENING PRESSUREPILOT RELEASE PRESSURESTROKES PER MINUTEOIL (LUBRICANT)AIR HOOK-UP Place picture of die in press here….SENSOR HOOK-UP

DIE PROTECTION ON OFFSHORT FEEDPART EJECT

CAM SWITCH ON OFFFEED ADVANCEPILOT RELEASE

TONNAGE REFERENCEDIE LOCATION TONNAGE

LEFT FRONTLEFT REARRIGHT FRONTRIGHT REAR

TOTAL TONNAGE

SHAKER REFERENCETYPE SIZE LOCATION COMMENTS

1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK.2.3.4.5.6.

Item ID Item Description

12 Micrometer 0-1" Mic - Material Thickness Verification3 Tape Measure Tape - Material Width Verification456789

10


SPECIAL CHARACTERISTICS LIST

PART NAME: PART NUMBER:

No. Description/Rationale Specification/Tolerance Class. Illustration/Pictorial1 -2 -3 -4 -

-

Predictive Maintenance Check ListDie Number: 0 Date:Indicate cycle

Cycle Frequency 50

,00

0

10

0,0

00

15

0,0

00

20

0,0

00

25

0,0

00

30

0,0

00

35

0,0

00

40

0,0

00

45

0,0

00

50

0,0

00

Punch/Bull Ring Mounting x x x x x x x x x x Check/tighten screwsWear Plates x Return to original sizes

Storage Cushions x x x x x x x x x x Check and/or replaceBalance Blocks x x x x x x x x x x Check and/or replace

Information Weight x x x x x x x x x x Check for LegibilityTags Nitro Pressure x x x x x x x x x x Check for Legibility

Danger x x x x x x x x x x Check for Legibility

Guidance Guide Pins x Check for wear, replace Guide Bushings x x Check for wear, replace

Lifters x x x x x Check for leaksCylinders x x x x x Check for leaks

Prox. Switches x x x x x x x x x x Check Cords x x x x x x x x x x Check Boxes x x x x x x x x x x Check

Surface Wear Cavity/Pad x x Check for surface damagePunch x x One or

Post x x the other

Plate type x x x x x x x x x x Check for damagePin type x x x x x x x x x x Check for damage

Punch Rubbing x x x x x x x x x x Check for damage

Nitro x Check Nitro Log and/or replaceAir x Replace

Internal Wear Plates x Return to original sizesPad Pins & Bushings x x Replace bushings/check pins

Gauging Rail Gauge x x x x x x x x x x Check for tight/position/damageSolid Gauge x x x x x x x x x x Check for tight/position/damage

Bottom Blocks x x Check for tight/position/damage

Comments:

Actual Time Spent

Checklist Completed By:

Complete

Do all activities marked with an "x"

"X"= Done. 0 = no action needed. NA = not in this die.Legend for complete column

PREVENTIVE MAINTENANCE WORK INSTRUCTIONControl Object: Use of this instruction will enable the Die Preventive Maintenance Areas to warrant the

tools that have been PM'd as fit for service when returned to their production line.Reason: This instruction serves as a reminder to the die maker to check critical areas on the

tools and repair/replace those areas that may be a problem during a production run.Responsibility: The die maker will perform this maintenance before returning the tools to production and

inform the supervisor of any problem that requires scheduled release time to correct.

Instructions:1) Check punch and resurface as needed

2) Check upper and lower Steels for wear. Repair as needed.

3) Check beads and gutters for wear. Repair as needed.

4) Check nitro cylinders for leaks. Replace as needed

5) Check lifter system for damage. Repair as needed

6) Check heel and wear plates for proper clearance and wear. Tighten/replace as needed.

7) Check risers and punch mounting plates for loose and missing screws. Tighten/replace as needed.

8) Clean disassembled die. Lubricate where necessary.

9) Check and re-size / re-shim equalizer blocks.

10) Check bolster plate mounting screws. Tighten/replace as needed.

Approval: Date:

Concurrence: Date:

Date Revised: Date Issued:

APQP Forms

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