PPAP-GenericExampleTemplateAM

7/30/2019 PPAP-GenericExampleTemplateAM

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Customer: Your company name

Customer Part Number: 1680995-101

Supplier Part Number 1680995-101

Part Name: Bushing, Guide Slot

Print Rev. Level: E

Drawing Dated: 2/1/2003

Doc. Revision Date: N/A

Doc. Original Date: 12/23/2005

Doc revision: 0

Project Engineer: John Smith

Quality Engineer Amy Millimen

Purchasing Jane Doe

Manufacturing Rep.: Bob Miller

Document Prepared by: Name

What changed? Document Name Date

Who made change?


2/20

Bushings R US, Inc.

Supplying Quality Bushings

- On Time - With Zero Defects - Is


3/20

Warrant Letter 1

Dimensional Layout 2

Material & Performance Testing 3

Capability Studies / MSA 4

Process Flow Chart 5

Control Plan 6

PFMEA 7

Marked Blueprint 8

Index

Bushings R US, Inc.


4/20

Control Plan

Key Contact/Phone Date (Original): Date (

Control Plan Number: 858-848-8000 N/APart Number/Latest Change Level: Core Team: John Smith Amy Millimen Customer Engineering Approval /

Jane DoeBob Miller

Part Name / Description: Supplier / Plant Approval / Date: Customer Quality Approval / Date

Supplier / Plant: Supplier Other Approval /Date (If Required): Other Approval / Date (If Required

Code:

Part/ Process Name/ Machine, Special

Process Operation Devices, No. Product Process Char. Product / Process Evaluation/ C

Number Description Jig, Tools, Class Specification/ Measurement Size Freq.

For Mfg. Tolerance Technique

10 Incoming n/a Receive to Bar Stock / Vespel Visual Inspection Lot 100% Verify

Inspection. inventory and SP-21 Mataerial of Material Mater

verify Physical Certification

properties Ref. P

20 Order entry & Customer Process Schedule based on Open PO Status One Per Order Produ

Scheduling Order Entry order and machine & material Report Quantity Order

and Scheduling schedule availability.

manufacturing Ref. P

30 Material handling Raw Bar Stock Pull from Per Work Order Visual Qty per Per Order Produ

inventory workorder Quantity/Lot Order

per prodution

work order Ref. P

40 Machining CNC Machining Raw Material, Machine to Run CNC program Visually verify Order First Piece Progra

Operation Center CNC Program drawing for specified part. correct program. Qty Set Up Dimen

specifications Verify critical Inspector todimensions per First verify first piece

Piece Inspection Plan. per inspection

plan. Ref. P

Robert Navarro

Sample

Characteristics Methods

12/23/2005

E

Bushing, Guide Slot

1680995-101

Prototype Pre-launch Production


5/20

Control Plan



Jane DoeBob Miller



Code:





Robert Navarro

Sample


12/23/2005

E

Bushing, Guide Slot

1680995-101


50 Quality Control - 3 OAL Verify 0.330" +/- 0.005 Calipers 30 pcs. Initial PPAP

5 Slot Width Critical 0.210 +/- 0.005 Calipers per cavity. PPAP and custom

Key, Special, and 10 Slot Diameter Dimensions 0.182 +/- 0.001 Gage Pin annually requireCritical Dimensions 8 OD 0.400 +/- 0.005 Diameter Gage

Ref. P

In Process 3 OAL 0.330" +/- 0.005 Calipers One First Piece SPC PInspection 5 Slot Width 0.210 +/- 0.005 Calipers and and per Monito

10 Slot Diameter 0.182 +/- 0.001 Gage Pin per sampling verific8 OD 0.400 +/- 0.005 Diameter Gage sampling plan

plan

Ref. P

n/a Visual Defects Visual No scratches, burrs, Visual Per 100% MasteInspection burns, or other visual Order

defects that may

affect the performance

of the product.

Ref P


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Control Plan



Jane DoeBob Miller



Code:





Robert Navarro

Sample


12/23/2005

E

Bushing, Guide Slot

1680995-101


70 Finished Goods Barcode n/a Boxed parts Scan parts to n/a Scan barcode label for Visual One Each box. Invent

scanning & scanner inventory each box, verify box detail,

storage & scanned qty match. verific

80 Pull from Barcode n/a Boxed parts per Pull parts from n/a Scan barcode label for Visual One Each box. Shippi

inventory & scanner shipping report. stock & scan each box, verify box shipm

stage for to shipment. & scanned qty match. repor.

shipment.

n/a n/a Boxed parts. Dock Audit n/a Visually inspect for Pass / Fail. One Each box. Finishhandling or storage Visually inspect form, q

damage. packaging. Ref. P

90 Shipping n/a Quantity Visually inspect n/a Load truck, have all Visual Per truck. Each Shippi

shipped to truck for documents signed as Shipment Packin

customer suitability & required. Lading

load.


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Potent ial

Failure Mode Effects Analysis (Process F

Item 1680995-101 Bushing, Guide Slot Process Responsibility

Model year(s)/Vehicle(s) Key Date

Core Team: Amy Millimen John Smith Jane Doe Bob Miller

Process Function

Requirements

Potential FailureMode

Potential Effect(s) of Failure SEV

C

L

A

S

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

OCC

Current Process ControlsPrevention

Current Process CDetection

Receive MaterialMaterialDamaged

Material unusable, InventoryShortage, Late shipment ofproduct

7 Damaged during shipping,improper material

handling at supplier

1 N/A Incoming Inspe

Receive productionpart orders &schedule partproduction runs.

Data entry error. Parts not scheduled to run(6). 6 Operator data entryerror(1)

1 Orders received electronically,data entry not required.

Orders are double cheaccuracy where data erequired.

Process dataaccurately.

Quantity over run (3). Quantityunder run (5).

3 Operator data entryerror(2)

2 Orders received electronically,data entry not required.

Orders are double cheaccuracy where data erequired.

Pull raw material andpackaging frominventory and deliver

Wrong materialissued

Customer parts do not meetprint material requirements(8)

8 Operator error readingwork order/raw materialpackaging(1)

1 Raw material is bar codeidentified and scanned to thework order to verify correct.

Operator at machining visually inspects materwork order.

Machine Bushings Wrong programuploaded

Customer parts do not meetprint dimensionalrequirments(8)

8 Operator error, wrongCNC program uploaded(2)

2 Operator verifies part number perworkorder and cross referencesto program part number.

First piece set up inspedrawing requirements

Per customerrequirements/dwg

Dimension doesnot meet printtolerance

Customer parts do not meetprint dimensionalrequirements(8)

8 Bar stock not centered inchuck(2), machine tool iswearing(5), programrequires adjustment(3)

5 First piece set up inspection SPC monitoring per sa

10 - Incoming Inspection

20 - Order Entry & Scheduling

30 - Material Handling

40 - Machining Operation.


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Potent ial

Failure Mode Effects Analysis (Process F

Item 1680995-101 Bushing, Guide Slot Process Responsibility

Model year(s)/Vehicle(s) Key Date

Core Team: Amy Millimen John Smith Jane Doe Bob Miller

Process Function

Requirements

Potential FailureMode

Potential Effect(s) of Failure SEV

C

L

A

S

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

OCC

Current Process ControlsPrevention

Current Process CDetection

Boxes placed in

wrong racklocation.

Late (4) or missed shipment

(5)

5 Warehouse personnel not

following procedure (1),mis-scanned rack location(2).

2 Computer system recommends

rack location via inventory partslist. Rack bays are all bar-coded.

Warehouse places par

computer recommendascans to rack location, data downloaded into i

80 - Pull from inventory & stage to shipment.

Pull from inventoryper shipping report,and scan & stage forshipment.

Containerdamage

Parts damaged (6), Customercomplaint (7)

7 Operator error (1), boxesstacked too high on skids(2)

2 Operator tow motor training. Internal stack height 4 (5), visual inspect for dFinished skids are shriwith corner protectors.

Accurate data forboth inventory &shipment purposes,boxes are stagedwithout damage forshipment.

Unable to findparts forshipment.

Late (4) or missed shipment(5)

5 Warehouse personnel notfollowing procedure (1),mis-scanned rack location(2).

2 Computer system idenlocation from scanned (4). Warehouse manadiscrepant ship list dailsearches for anything m

90 - Shipping

Inspect & load partson truck.

Missing Paperwork.

Late (4) or missed shipment(5)

5 Warehouse personnel notfollowing procedure (1),special instructions listedon shipping report not

followed (1).

1 Special paperwork oftewith advanced shippingTruck drivers must revpacking slip & bills of la

pick-up (4).

Truck to suitable totransport partswithout damage.

Containerdamage

Parts damaged (6), Customercomplaint (7)

7 Operator error (1), boxesstacked too high on skids(2)

2 Operator tow motor training. Internal stack height 4 (5), visual inspect for d


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Process Flow

Customer: Your company name Document Created:Part Number: 1680995-101 Document Revised:Part Name: Bushing, Guide Slot Part Revision Level:

ProcessNo. Operation Transport Inspect Store Idle

10 - Delivery of : Raw material, packaging items, components, and non stock items.

- Incoming inspection. Documentation / Bills of lading checked, visual inspect fordamage. samples taken & measured per incoming inspection plan.- Raw material / components are labeled after inspection. Inventory updated.

- Received items moved to appropriate areas.

20 - Order received from customer

- Production Planning generates a work order according to open order maintenanceand part classification criteria.- The work order & barcodes are posted to the production scheduling board.

Mfg. enters order in the system per work order.30 - Warehouse personnel prints material issue slip.

- Warehouse personnel pulls packaging, components, etc. required from appropriate

rack location per Work Order requirements.- Material handler delivers to appropriate manufacturing location.

40 - Set-up/Process Tech prints set up sheet, and loads appropriate CNC program

per part number.- Set-up/Process Tech runs intial part and verifies criticals per set up instructions,

making any adjustments necessary.- Process parameters are locked and the machining center is given approval to run.

50 - Process Tech is to verify and document process settings on the Tracking Sheet.- Inspector packers pulls parts per sampling inspection plan and 100% visually

inspects parts.- Quality Inspector performs in-process dimensional inspection of pulled parts

per the sampling inspection plan and records data into the process monitoring system.60 - Accumulated production parts added to appropriate containers, per work order,

and Job Instruction.B titi fi d i i t i h l

Mac

hining

Opera

tion

Order

En

try

&

Sc

he

du

ling

E

N/A

12/23/2005

Pro

duc

tion

/Qua

lity

Con

tro

l

/

Incom

ing

Insp.

Ma

terial

Han

dling


10/20

Process Flow

Customer: Your company name Document Created:Part Number: 1680995-101 Document Revised:Part Name: Bushing, Guide Slot Part Revision Level:

ProcessNo. Operation Transport Inspect Store Idle

E

N/A

12/23/2005

80 - Customer Service issues shipping report, staged in Warehouse shippingboard.- Warehouse personnel pull required quantities from finished goods and

places in staging.- Boxes / containers are visually inspected for damage/deterioration. Barcodes

are scanned from inventory and assigned to shipment.- Skids / boxes are wrapped etc per customer requirements. (corner

protectors, allowed stack heights, etc.)90 - Truck arrives to pick-up shipment.

- Shipping personnel visual inspect truck for suitability of transport.- Finished boxes loaded to truck.

- Shipping personnel send advanced notice to customer.

Pu

llfrom

inven

tory

&

stage

tos

hipmen

t.

Shipp

ing


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Part Submission Warrant

Part Name Part Number

Safety and/orGovernment Regulation Yes No Engineering Drawing Change Level Dated 2/1/2003

Additional Engineering Changes NA Dated N/A

Shown on Drawing no. Purchase order No. Weight (kg)

Checking Aid No. NA Engineering Change Level NA Dated NA

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Bushings R Us Inc. 6666666666 Dimensional Material/Functional AppearanceSupplier Name Supplier Code

12345 Main St. Customer Name / Division Your company nameStreet Address Buyer/ Buyer Code Don Anderson

Pleasantville, CA Application Edge, CastleCity 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 LocationTooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant, only (and for designated 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.

Bushing, Guide Slot

E

1680995-101

0.08911680995

98765


12/20

PART NO: 1680995-101 DATE: 12/24/2005 ISSUE NO.PART NAME: Bushing, Guide Slot SUPPLIER NAME: BUSHINGS R US INC.

LOT NO: 123456 TYPE OF DEVIATIONRESPONSIBILITY: AMY MILLIMEN LIMITED QUANTITY LIFETIMEPROGRESS X INITIALOF PARTS MASS PROD. LIMITED PRODUCTION DATE

DESCRIPTION OF NONCONFORMITY:

Print item 1, chamfer width of 0.03" 0.01 measured oversized for 1 of 3 measured samples.We are requesting a temporary deviation to ship parts with this non-conformity until we exhaust the 300 piecePPAP sample parts produced. The feature is only oversized by 0.01", and will not affect the function of

the assembly.

JUDGEMENT (FOR DELTA DESIGN USE ONLY)CATEGORY OF APPROVAL

Quanitity: From/To Date:

REASONS AND COMMENTS

ENGINEERING SECTION

RESPONSIBLE PERSON/DATEACCEPT

REJECT

DEVIATION REQUEST SHEET

SIGNATUREJudgement

X

LIMITED QTY LIMITED TIME PERMANENT


13/20

Production Part Approval -

Material Test Results

SUPPLIER PART NUMBER

Bushings R US 1680995-101

NAME OF INSPECTION FACILITY PART NAME

Bushing, Guide Slot

TYPE OFTEST

OKNOTOK

Engineering Change Level: E x

Specification Number: Vespel SP-21 x

Date of Specification: 10/31/2001 x

Material Supplier: Material Warehouse x

Material Description: Vespel SP-21 x

Material Certification Date: 12/01/2005 x

SUPPLIER TEST RESULTSMATERIAL SPEC. NO./DATE/SPECIFICATION


14/20

Page 14 of 20Production Part Approval

Performance Test Results

1680995-101

Ref.No.

TestFreq.

Qty.Tested

OKNotOK

Supplier Test Results and Test Conditions

Name of Laboratory

Bushing, Guide Slot

Part Number

Part NameBUSHINGS R US

Supplier

REQUIREMENTS

No Performance Testing is Required


15/20

Production Part Approval -

Dimensional ResultsSUPPLIER PART NUMBER

Bushings R Us 1680995-101NAME OF INSPECTION FACILITY PART NAME

Internal Inspection Bushing, Guide Slot

Item Dimenson (in) Tolerance Type Sample 1 Sample 2 Sample 3 OK

OK

1a 0.03 0.01 .05 0.04 0.03 X

1b 45 1.0 45 45 46 X

2 3.01 + 0.001 / -0.000 3.010 3.011 3.011 X

3 0.330 0.005 0.332 0.331 0.33 X

4 0.080 0.005 0.082 0.082 0.08 X

5 0.21 0.005 0.211 0.213 0.212 X

6 0.010 A 0.008 0.005 0.006 X

7 Full Radius OK OK OK X

8 0.400 0.005 0.400 0.400 0.401 X

9 TP 0.005 0.004 0.003 0.004 X

10 0.182 0.001 0.182 0.182 0.181 X

11 Material Vespel SP-21 SEE MATERIAL CERT X

12 Edge Radius Callout OK OK OK X

13 OK OK OK X

Supplier Measurement Results

Part Number, dash number, rev perDelta standard.


16/20

Production Part Approval -Initial Process Study


1680995-101NAME OF INSPECTION FACILITY PART NAME

Bushing, Guide SlotDimension: 0.210 0.08

USL: 0.215 0.085LSL: 0.205 0.075

1 0.210 0.0772 0.211 0.0813 0.210 0.0814 0.213 0.0815 0.210 0.0776 0.210 0.0817 0.209 0.0808 0.210 0.0819 0.210 0.08110 0.210 0.08111 0.210 0.08112 0.210 0.081

13 0.210 0.08114 0.210 0.08115 0.210 0.08116 0.210 0.08117 0.210 0.08118 0.210 0.08119 0.210 0.08120 0.210 0.08121 0.210 0.08122 0.210 0.081

23 0.210 0.08124 0.210 0.08125 0.210 0.08126 0.210 0.08127 0.210 0.08128 0.210 0.08129 0.210 0.08130 0.210 0.08031 0 210 0 081

Bushings R US


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USL: 0.215 0.085LSL: 0.205 0.075

Bushings R US

48 0.211 0.08149 0.210 0.08150 0.210 0.081

51 0.210 0.08152 0.210 0.08153 0.210 0.08154 0.210 0.08155 0.210 0.08156 0.210 0.08157 0.210 0.08158 0.209 0.08159 0.209 0.08160 0.209 0.081

61 0.209 0.08162 0.209 0.08163 0.209 0.08164 0.209 0.08165 0.209 0.08166 0.209 0.08167 0.209 0.08068 0.209 0.08169 0.209 0.08170 0.209 0.081

71 0.211 0.07872 0.210 0.07773 0.211 0.07774 0.210 0.08175 0.210 0.08176 0.210 0.08077 0.209 0.08178 0.209 0.08279 0 210 0 081


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USL: 0.215 0.085LSL: 0.205 0.075

Bushings R US

99 0.209 0.080100 0.208 0.081

Mean 0.210 0.081 #DIV/0! #DIV/0! #DIV/0! #DIV/0!Std Dev. 0.000887896 0.00106534 #DIV/0! #DIV/0! #DIV/0! #DIV/0!Cp 1.877097575 1.564445656 #DIV/0! #DIV/0! #DIV/0! #DIV/0!

CpU 1.893991454 1.38296996 #DIV/0! #DIV/0! #DIV/0! #DIV/0!CpL 1.860203697 1.745921352 #DIV/0! #DIV/0! #DIV/0! #DIV/0!CpK 1.860203697 1.38296996 #DIV/0! #DIV/0! #DIV/0! #DIV/0!


19/20

Part Number Gage Type:

Dimension Gage ID:

Tolerance Date:

Gage R&R 1 2 3 4 5 6 7 8 9 10 Average

Trial 1 0.21 0.21 0.213 0.21 0.211 0.21 0.21 0.21 0.21 0.21Operator 1 Trial2 0.21 0.21 0.213 0.211 0.211 0.21 0.21 0.211 0.21 0.21

Trial 3 0.21 0.21 0.213 0.211 0.211 0.21 0.21 0.211 0.21 0.21 0.21053 Xbar1Range1 0 0 0 0.001 0 0 0 0.001 0 0 0.0002 Rbar1Trial 1 0.21 0.21 0.212 0.21 0.211 0.21 0.211 0.21 0.21 0.21

Operator 2 Trial2 0.211 0.21 0.212 0.211 0.21 0.21 0.21 0.211 0.21 0.21Trial 3 0.21 0.21 0.213 0.211 0.211 0.21 0.21 0.211 0.21 0.21 0.2105 Xbar2

Range2 0.001 0 0.001 0.001 0.001 0 0.001 0.001 0 0 0.0006 Rbar2Trial 1

Operator 3 Trial2

(if only 2 ops, Trial 3 Xbar3Clear C11:L13) Range3 Rbar3

K3 3.65 2.7 2.3 2.08 1.93 1.82 1.74 1.67 1.62Part Averages 0.210 0.210 0.213 0.211 0.211 0.210 0.210 0.211 0.210 0.210 0.003 Range of

Part AveragesRange Average 0.0004 ConstantsXDiff 0.0000 2 Trials 3 Trials # Trials 2UCL 0.0010 3.27 2.58 D4 2.58 UCL represents the limit of the individual R'sLCL 0.0000 0 0 D3 0 Circle those beyond the limit.Repeatability 0.0012 4.56 3.05 K1 3.05 Identify and correct causes

Reproducibility 0.0001 3.65 2.7 K2 3.65 LCL = 0 D3=0 for up to 7 trialsGage Capability 0.0012 2 Ops 3 OperatorsSpec Tolerance 0.0200

Acceptability(%) 0.06

AIAG - Automotive Industry Action Group FormulasEV 0.0012 Equipment Variation (EV)%EV 27.2% # Parts #Trials % of Total Variation (TV)

AV: 0.00000 10 3 Appraiser Variation(AV)%AV 0.0% % of Total Variation (TV)

R&R 0.0012 Repeatability and Reproducibility (R&R)%R&R 27.2% % of Total Variation (TV)PV 0.0043 Part Variation (PV)%PV 96.2% % of Total Variation (TV)TV 0.0045 Total Variation (TV)

1680995-1010.2100.005

CalipersCal001012/23/2005


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Gage system may be acceptable based on importance of application and cost

Instructions Just enter your measurement data in Cells C3:L5, C7:L9, C11:C13The template will automatically calculate all of the values based on your data

Gage Repeatability and ReproducibilityMeasurement is one common cause of variation. Gage R&R helps improve measurementIf repeatability is large compared to reproducibility, reasons include:1. gage instrument needs maintenance2. gage needs to be redesigned3. clamping or location needs to be improved4. excessive within-part variation

If reproducibility is large compared to repeatability, reasons include:1. Operator needs to be better trained inhow to use and read gage2. Calibrations on gage are not clear

3. Fixture requred to help operator use gage more consistently

Gage System Acceptability%R&R

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