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FCD # 0427a Rev 1

Part Submission WarrantPart Name Bradley Part Number Bradley Part Rev

Shown on Bradley Drawing Number Drawing Rev Dated

Supplier Part Number Supplier Drawing Number Drawing Rev Dated

Safety and/or Government Regulation Purchase Order No. Weight (lbs)

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Supplier Company Name Supplier Vendor Number Customer Name:

Additional Manufacturing Sites Bradley Manufacturing Locations using the part (list all)

Street Address Purchasing Representative

City State Zip

Does this part utilize Bradley owned tooling? Is it properly identified?

Toot Asset #

REASON FOR SUBMISSION

Initial submission (New Parts and Part Number Changes) New Supplier, New material or new source for existing materialEngineering Change: New/Revised drawing or other specification Change of supplier, material or non-equivalent materials/services

New process or a change in production process or method

Correction of Non-conformance or discrepancy Change of manufacturing location, sub-supplier or additional locationChange to optional construction, material or component Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

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 in Explanation/comments section below )Is this a multicavity tool? How many Cavities/Spindle (for molds or dies) ? Number of parts submitted by cavity/spindle

DECLARATIONI affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 4th Edition

requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regular production

process. The data and samples were produced at the production rate of in on Any deviations to this warrant submission

are noted below in the explanation/comments section. #parts # hours date

EXPLANATION/COMMENTS:

Print Name: Job Title Phone No. Fax No.

Supplier Authorized Signature Date Email

FOR BRADLEY CORPORATION USE ONLY

PPAP Warrant Disposition: Approved Rejected Interim

Bradley Engineering Approval : Date

Signature Print Name

Bradley Quality Approval : Date

Signature Print Name

IR # : R&D Request # PPAP #

If yes, P.O. #

Tooling: transfer, replacement (new), refurbishment, modified or additional

Level 1 - Warrant only submitted to the customer Level 2 - Warrant with product samples amd limiting supporting data.Level 3 - Warrant with product samples and complete supporting data. Level 4 - Warrant and other requirements as defined by Bradley.

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

YES NO

Yes No

Yes No

YES NO

C4

Part Name from Bradley Drawing

I4

Part Number from Bradley Drawing

P4

Part Revision

F6

Bradley Drawing Number

L6

Bradley Drawing Revision

D8

Enter is different from Bradley Part Number

H8

Enter Supplier Drawing Number

L8

Insert Supplier Drawing Revision

M10

Enter this number as found on the first production release purchase order.

Q10

Enter the actual weight in pounds to four decimal places. Must be weight of a completely finished part.

B13

Full Name of Company or Division.

G13

Supplier Vendor number as assigned by Bradley

J13

Bradley Division Name(s) Example: Bradley - Fixtures Bradley - Accessories Mills Company

B15

List all locations producing the part for Bradley use.

J15

List all division manufacturing sites that use this part:

J17

Buyer who has been your primary contact for business with Bradley.

Q23

Add Tooling PO#

Q25

Enter Bradley Tool Asset Number

F27

Check the appropriate box. Add explanatory details in the "other" section

H34

Identify the submission level requested by Bradley that you are submitting to.

F41

Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data if included in the submission. Level 3, 4 and 5 submissions typically require all sections.

J44

Please provide details on the number of molds. cavities or production processes within the overall production of the part reflected on the submission.

F52

Provide any explanatory details on the submission results, additional information may be attached as appropriate. Be sure to clearly state any known deviations.

D57

Name of individual responsible for preparing the part submission.

F59

The responsible supplier official, after verifying that the results show conformance to all customer requirements and that all required documentation is available shall approve the declaration and provide title, phone number, fax number and email address.

FCD # 0427b Rev 1

PPAP Submission ChecklistPart Number Bradley Facility PPAP Submission Due Date:

Part Rev LevelPrint Number Supplier Name

Print Rev PPAP Submission LevelPart Description Supplier Code

Project TeamROLE BRADLEY SUPPLIER

PurchasingQualityDesign

ManufacturingProject Management

Submission Element Required Documents Req Type Additional Comments

1 Bradley PSW Form

2 PPAP Checklist Bradley PPAP Checklist

3

4 Design FMEA

5 Flow Chart Any standard process flow format

6 Process FMEA Bradley or AIAG compliant form

7

8

9

10

11 Initial Process Studies

12 Outside Lab proof of Accreditation

13 AIAG compliant AAR Form

14 Sample Products

15 Checking Aids

16

17 Bradley Specification Deviation Form

ElementOrder

Element Status

Part Submission Warrant (PSW)

Bubbled Part Print & Engineering Records

Annotated Part Print along with any other associated Design records

Required only for Design Responsbile Suppliers. Bradley or AIAG compliant form

Control Plan/Quality Plan

Bradley form or any standard format for Control/Quality Plan.

Measurement System Analysis

Bradley GR&R form or a recognized statistical analysis tool package

Dimensional Test Results

Full Dimensional Layout on Bradley or Supplier form. Minimum 5 samples required comprising of samples from each cavity.

Material, Performance Test Results

Industry Standard reports or test result formats designated by Bradley.

Bradley CTQ Verification Form along with a recognized statistical analysis tool package

Qualified Lab Documentation

Appearance Approval Report

Identify samples with Bradley "Sample Product Tag". Minimum 1 part per cavity/production stream is required

Design & Certification documents for any checking aids employed in the process

Tooling Information Form

Required for Bradley owned tooling. Bradley Tooling Information Form.

Specification Deviation Form

FCD # 0427b Rev 1

Req Type : S - Submission of Element is Required IA - Submission of Element is Required If Applicable N - Submission of Element is Waived

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FCD # 0427c Rev 1

Part # Process Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Pro

cess

Num

ber

Requirements

Current Process Controls Action Results

Prevention Detection Actions Taken

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Potential Failure Modes and Effects AnalysisProcess FMEA

Please indicate EITHER: 1.) A designated RPN threshold for this process 2.) A target percentage of steps to be addressed. Check One

Process/StepFunction

Potential Failure Mode

Potential Effects of Failure

SEV

Class

Potential Cause(s)/Failure Mechanisms

OCC

DET

RPN

RecommendedAction(s)

Responsibility and

Completion Date

SEV

OCC

DET

RPN

N1

Either a target percentage or RPN threshold is determined by the organization owning the process. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, in a specific process your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the PFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1

Number for either percentage or threshold.

C3

Cooper Part Number as stated on Bradley Print.

I3

Department group or supplier name responsible for the process.

P3

Insert PFMEA Document Number

C4

Name of the System or component for which the process is being analyzed.

I4

Phone number or email of person responsible for completing Information.

P4

Company and person responsible for preparing PFMEA

C5

Most recent revision off of Bradley Print

I5

Enter the initial due date of the PFMEA which should not exceed start of production.

P5

Enter the date the original PFMEA was compiled.

C6

Identify the Core Team members for the PFMEA activity.

I6

Indicate the location city and state of the Bradley manufacturing facility that you are providing parts to.

P6

Insert date of latest revision to PFMEA

A8

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B8

List the process function that corresponds to each process step or operation being analyzed. .

C8

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D8

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E8

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

F8

How Severe is the Effect on the Product SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK EFFECT SEVERITY OF EFFECT ON THE PROCESS Failure to meet safety Potential failure mode affects safe product operation 10 Failure to meet Safety May endanger operator (machine/assembly) without warning and/or regulatory and/or involves noncompliance with regulatory standards. Safety and/or regulatory requirements requirments. Potential failure mode affects safe product operation 9 May endanger operator(machine/assembly) without warning and/or involves noncompliance with regulatory standards Loss or degradation Loss of primary function (product inoperable, does not 8 Major Disruption 100% of product may have to be scrapped. Line shutdown of primary function affect safe prodyct operation). or stop shipment. Degradation of primary function (product inoperable, 7 Significant Disruption A portion of production run may have to be scrapped. Deviation but at a reduced level of performance.) from primary process including decreased line speed or added manpower. Loss or degradtion Loss of secondary function(product operable, but 6 Moderate Disruption 100% of production run may have to be reworked off line and of secondary function comfort/convience functions at a reduced level of performance. accepted. Degradation of secondary function (product inoperable, but 5 A portion of the production run may have to be reworked comfort/convience functions at a reducted level. offline and accepted. Annoyance Appearance, noise or minor issue, product operable, item does 4 100% of production run may have to be reworked in station not conform and noticed by most customers (>75%) before it is processed. Appearance, noise or minor issue, product does not conform, 3 A portion of the production run may have to be reworked and noticed by many customers (50%). in station before it is processed. Appearance, noise or minor issue, product does not conform 2 Minor Disruption Slight inconvenience to process, operation or operator and noticed by many customers (<25%). No effect No discernable effect 1 No Effect No discernible effect

G8

How Severe is the effect to the customer? Identified product or process characteristics!

H8

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

I8

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥ 100 per thousand pieces VERY HIGH 9 ≥ 50 per thousand pieces HIGH 8 ≥ 20 per thousand pieces HIGH 7 ≥ 10 per thousand pieces HIGH 6 ≥ 2 per thousand pieces MODERATE 5 ≥ .5 per thousand pieces MODERATE 4 ≥ .1 per thousand pieces MODERATE 3 ≥ .01 per thousand pieces LOW 2 ≥ .001 per thousand pieces LOW 1 Failure is elimenated through preventative control VERY LOW

J8

What are the existing controls and procedures (inspection and test) that either prevent failure mode from occurring or detect the failure should it occur? The preferred approach is always prevention!

L8

How well can you detect cause or failure mode? RATING CRITERIA Suggested Detection Methods Detection Types 10 No Detection Opportunity Cannot detect or is not checked ALMOST IMPOSSIBLE Manual 9 Not likely to detect at any stage. Error not easily detected indirect VERY REMOTE Manual or random checks. 8 Problem detection post processing Detection by visual/tactile/audible means. REMOTE Manual 7 Problem Detection at Source Attribute Gauging/Post Processing-or Visual VERY LOW Manual 6 Problem Detection Post Processing Control is achieved with charting (SPC) LOW Gauging,Manual 5 Problem Detection at Source Detection is based on 100% gauging on set up MODERATE Gauging Performed on set-up of first piece check up 4 Problem Detection at Post Processing Detection Post Processing that will lock MODERATELY HIGH Error Proof,Gauging part from further processing 3 Pronblem Detection at Source Error detection in station or in HIGH Error Proof, Gauging will detect error and prevent processing 2 Error Detection Problem Prevention Detection in station by controls VERY HIGH Error Proof, that will prevent part from being made 1 Detection not applicable; Error prevention as a result of product . ALMOST CERTAIN Error Proof design. Item has been error proofed.

M8

SEV x OCC x DET

N8

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O8

Who is responsible for the recommended action? What is the target completion date.

J9

List the methods used that eliminate or prevent the cause of failure.

K9

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P9

List the completed actions that are included in the recalculated RPN. Include the implementation date for any changes.

Q9

What is the new severity based on the action applied.

R9

What is the new Occurrence numbers based on the action taken.

S9

What is the new detection ranking based on the action taken. Has the detection improved?

T9

Recompute RPN after actions are complete.

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FCD # 0427c Rev 1

Part # Process Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Pro

cess

Num

ber

Requirements

Current Process Controls Action Results

Prevention Detection Actions Taken

Potential Failure Modes and Effects AnalysisProcess FMEA

Please indicate EITHER: 1.) A designated RPN threshold for this process 2.) A target percentage of steps to be addressed. Check One

Process/StepFunction

Potential Failure Mode

Potential Effects of Failure

SEV

Class

Potential Cause(s)/Failure Mechanisms

OCC

DET

RPN

RecommendedAction(s)

Responsibility and

Completion Date

SEV

OCC

DET

RPN

0 0

0 0

0 0

0 0

0 0

N1

Either a target percentage or RPN threshold is determined by the organization owning the process. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, in a specific process your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the PFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1

Number for either percentage or threshold.

C3

Cooper Part Number as stated on Bradley Print.

I3

Department group or supplier name responsible for the process.

P3

Insert PFMEA Document Number

C4

Name of the System or component for which the process is being analyzed.

I4

Phone number or email of person responsible for completing Information.

P4

Company and person responsible for preparing PFMEA

C5

Most recent revision off of Bradley Print

I5

Enter the initial due date of the PFMEA which should not exceed start of production.

P5

Enter the date the original PFMEA was compiled.

C6

Identify the Core Team members for the PFMEA activity.

I6

Indicate the location city and state of the Bradley manufacturing facility that you are providing parts to.

P6

Insert date of latest revision to PFMEA

A8

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B8

List the process function that corresponds to each process step or operation being analyzed. .

C8

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D8

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E8

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

F8

How Severe is the Effect on the Product SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK EFFECT SEVERITY OF EFFECT ON THE PROCESS Failure to meet safety Potential failure mode affects safe product operation 10 Failure to meet Safety May endanger operator (machine/assembly) without warning and/or regulatory and/or involves noncompliance with regulatory standards. Safety and/or regulatory requirements requirments. Potential failure mode affects safe product operation 9 May endanger operator(machine/assembly) without warning and/or involves noncompliance with regulatory standards Loss or degradation Loss of primary function (product inoperable, does not 8 Major Disruption 100% of product may have to be scrapped. Line shutdown of primary function affect safe prodyct operation). or stop shipment. Degradation of primary function (product inoperable, 7 Significant Disruption A portion of production run may have to be scrapped. Deviation but at a reduced level of performance.) from primary process including decreased line speed or added manpower. Loss or degradtion Loss of secondary function(product operable, but 6 Moderate Disruption 100% of production run may have to be reworked off line and of secondary function comfort/convience functions at a reduced level of performance. accepted. Degradation of secondary function (product inoperable, but 5 A portion of the production run may have to be reworked comfort/convience functions at a reducted level. offline and accepted. Annoyance Appearance, noise or minor issue, product operable, item does 4 100% of production run may have to be reworked in station not conform and noticed by most customers (>75%) before it is processed. Appearance, noise or minor issue, product does not conform, 3 A portion of the production run may have to be reworked and noticed by many customers (50%). in station before it is processed. Appearance, noise or minor issue, product does not conform 2 Minor Disruption Slight inconvenience to process, operation or operator and noticed by many customers (<25%). No effect No discernable effect 1 No Effect No discernible effect

G8

How Severe is the effect to the customer? Identified product or process characteristics!

H8

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

I8

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥ 100 per thousand pieces VERY HIGH 9 ≥ 50 per thousand pieces HIGH 8 ≥ 20 per thousand pieces HIGH 7 ≥ 10 per thousand pieces HIGH 6 ≥ 2 per thousand pieces MODERATE 5 ≥ .5 per thousand pieces MODERATE 4 ≥ .1 per thousand pieces MODERATE 3 ≥ .01 per thousand pieces LOW 2 ≥ .001 per thousand pieces LOW 1 Failure is elimenated through preventative control VERY LOW

J8

What are the existing controls and procedures (inspection and test) that either prevent failure mode from occurring or detect the failure should it occur? The preferred approach is always prevention!

L8

How well can you detect cause or failure mode? RATING CRITERIA Suggested Detection Methods Detection Types 10 No Detection Opportunity Cannot detect or is not checked ALMOST IMPOSSIBLE Manual 9 Not likely to detect at any stage. Error not easily detected indirect VERY REMOTE Manual or random checks. 8 Problem detection post processing Detection by visual/tactile/audible means. REMOTE Manual 7 Problem Detection at Source Attribute Gauging/Post Processing-or Visual VERY LOW Manual 6 Problem Detection Post Processing Control is achieved with charting (SPC) LOW Gauging,Manual 5 Problem Detection at Source Detection is based on 100% gauging on set up MODERATE Gauging Performed on set-up of first piece check up 4 Problem Detection at Post Processing Detection Post Processing that will lock MODERATELY HIGH Error Proof,Gauging part from further processing 3 Pronblem Detection at Source Error detection in station or in HIGH Error Proof, Gauging will detect error and prevent processing 2 Error Detection Problem Prevention Detection in station by controls VERY HIGH Error Proof, that will prevent part from being made 1 Detection not applicable; Error prevention as a result of product . ALMOST CERTAIN Error Proof design. Item has been error proofed.

M8

SEV x OCC x DET

N8

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O8

Who is responsible for the recommended action? What is the target completion date.

J9

List the methods used that eliminate or prevent the cause of failure.

K9

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P9

List the completed actions that are included in the recalculated RPN. Include the implementation date for any changes.

Q9

What is the new severity based on the action applied.

R9

What is the new Occurrence numbers based on the action taken.

S9

What is the new detection ranking based on the action taken. Has the detection improved?

T9

Recompute RPN after actions are complete.

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FCD # 0427d Rev 1

Control PlanControl Plan Number Key Contact / Phone Date (Orig.) Current Release Level Current Release Date

Part Number/ Latest Change (Rev) Level Part Description Supplier Code Plant Location

Core Team Supplier Name Quality Department Approval

Customer Engineering Approval / Date (If Req'd) Supplier Plant Approval Other Approval / Date (If Req'd)

CHARACTERISTICSMETHODS

CONTROL METHOD REACTION PLAN

SAMPLE

NO. PRODUCT PROCESS SIZE

FREQ

PAR

T /

PRO

CES

S N

UMB

ER PROCESS NAME / OPERATION

DESCRIPTION

MACHINE DEVICES / JIG / TOOLS FOR

MANUFACTURING

SPECIAL CHAR. CLASS

PRODUCT / PROCESS / SPECIFICATION /

TOLERANCE

EVALUATION/MEASUREMENT

TECHNIQUE

Prototype Pre-ProductionProduction

A3

This is the internal document number used to track and control the Control Plan.

D3

This is the key quality person responsible for developing and leading the control plan strategy.

H3

This is the date of original release of the control plan for the part number.

I3

This is the Revision level of the most current CONTROL PLAN release.

L3

Date the current control plan was released or became effective.

A5

Enter the part number and the most current revision level.

E5

Enter the description of the part on the Bradley print.

I5

Supplier code assigned by Bradley

L5

Location of the current plant.

A7

List all key team members involved in the process and the control plan. List names, numbers and other contact information.

F7

Full Name of Supplier

I7

Signature of author or quality approval of control plan.

A9

Customer or Bradley Engineering approval (if required)

F9

Supplier Management signature of the control plan indicating executive level approval of the control plan.

I9

Any additional approvals required.

A11

The item number is usually referenced from the process flow chart. If multiple part numbers exist (assembly) list the individual part numbers and their processes accordingly.

B11

All steps in the manufacturing of a system, subsystem or component are described. Identify the process/operation that best describes the activity on each line.

C11

For each operation that is described, identify the processing equipment, machine, device, jig or other tool for manufacturing as appropriate.

D11

A distinguishing feature, dimension or property of a process or it's output on which variable or attribute data can be collected.

G11

Use the appropriate characteristic as defined by Bradley Engineering (eg. CTQ)

H11

Systematic plan for controlling a process.

L11

Brief description of how the operation will be controlled, including procedure numbers where applicable. Should be based on effective analysis of the process. Various methods can be used from additional inspection to SPC or error proofing. The method of control should be clinically evaluated for effectiveness of process control.

M11

The reaction plan specifies the corrective actions necessary to avoid producing nonconforming products or operating out of control. The actions should normally be the responsibility of the people closest to the process.

H12

Specification/tolerance may be obtained from various engineering documents such as drawings, specifications etc..

I12

Measurement system being used to check the specification or tolerance. This could include gages, fixtures, tools and or test equipment required to measure the part/process/manufacturing equipment. A measurement system analysis should be done to ensure control of monitoring and measuring devices prior to relying on a measurement system.

J12

When sampling is required list the corresponding sample size and frequency.

D13

Cross reference number from all applicable documents such as FMEAS, process flows etc..

E13

Product characteristics are the features or properties of a part that are described on the drawings or other primary engineering information. The Core Team should identify the special Product Characteristics from all sources. All special characteristics should be listed on the Control Plan.

F13

Process Characteristics are the process variables that have a cause and effect relationship with the identified Product Characteristic. A Process Characteristic can only be measured at the time it occurs. The Core Team should identify Process Characteristics for which variation must be controlled to minimize variation. There could be one or more Process Characteristics listed for each Product Characteristic. In some processes one Process Characteristic may affect several Product Characteristics.

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FCD # 0427d Rev 1

Control PlanControl Plan Number Key Contact / Phone Date (Orig.) Current Release Level Current Release Date

Part Number/ Latest Change (Rev) Level Part Description Supplier Code Plant Location

Core Team Supplier Name Quality Department Approval

Customer Engineering Approval / Date (If Req'd) Supplier Plant Approval Other Approval / Date (If Req'd)

Prototype Pre-ProductionProduction

A3

This is the internal document number used to track and control the Control Plan.

D3

This is the key quality person responsible for developing and leading the control plan strategy.

H3

This is the date of original release of the control plan for the part number.

I3

This is the Revision level of the most current CONTROL PLAN release.

L3

Date the current control plan was released or became effective.

A5

Enter the part number and the most current revision level.

E5

Enter the description of the part on the Bradley print.

I5

Supplier code assigned by Bradley

L5

Location of the current plant.

A7

List all key team members involved in the process and the control plan. List names, numbers and other contact information.

F7

Full Name of Supplier

I7

Signature of author or quality approval of control plan.

FCD # 0427e Rev 1

GR&R Study - Multiple Operators

Part Number: Supplier Name: DateDrawing Number: Supplier Address:

Drawing Rev.: Supplier ContactRev. Date:

Drawing Location: PCA Supplier Name: GR&R ContactPart Feature: PCA Address:

Feature Symbol: PCA ContactOther Information

Calibration Date: Gage Type: Gage ID: Unit of Measure:

Operator 1 Name Operator 2 Name Operator 3 Name

0 0 0USL LSL Number of Trials: Number of Operators:

Operator 1 Operator 2 Operator 3Part # 1st Trial 2nd Trial 3rd Trial Range 1st Trial 2nd Trial 3rd Trial Range 1st Trial 2nd Trial 3rd Trial Range

1 Error Error Error2 Error Error Error3 Error Error Error4 Error Error Error5 Error Error Error6 Error Error Error7 Error Error Error8 Error Error Error9 Error Error Error10 Error Error Error

* A minimum of six samples for each trial is required for these results to be valid

Gage R&R Summary Gage R&R DispositionMeasurement Unit Analysis

Disposition #VALUE!Repeatability: EV= #VALUE!Reproducability: AV= #VALUE!

R&R= #VALUE!Part Variation: PV = #N/A

Pass - Gage System is UseableTotal Variation: TV= #VALUE!

% Process Variation (TV) / % Tolerance Variation (TOL)#VALUE! #VALUE!#VALUE! #VALUE!#VALUE! #VALUE!

Fail - Gage System is Unstable#N/A

Gage Repeatability & Reproducibility worksheet for 10x2x2 or 10x3x3 Variable measurement study

GR&RTOL% < 10

10 ≤ GR&RTOL% ≤ 30 Gage System is useable but marginal% Equipment Variation (EVTV) %EVTOL

% Appraiser Variation (AVTV) %AVTOL

%GR&R (GR&RTV) %GR&RTOL

GR&RTOL% > 30%Part Variation (PVTV)

1 2 3 4 5 6 7 8 9 10

0.000

2.000

4.000

6.000

8.000

10.000

12.000

Part Operator AverageMost part averages should be outside the

control limits

UCLx LCLx Bar-X Op1 X Op2 XOp3 X

Ope

rato

r X

Valu

es

1 2 3 4 5 6 7 8 9 100

2

4

6

8

10

12

Repeatability Range (All Operators)

UCLr Bar-R Op1 Range Op2 RangeOp3 Range

Sample Number

Bar

R

D5

Part number as it appears on the Bradley Part Print.

H5

Full name of supplier

D6

Drawing number listed on Bradley drawing

H6

Enter supplier address

J6

Enter the date(s) the data was compiled

D7

Most recent revision number taken from Bradley print

D8

Date revision was completed

J8

Contact representative at Supplier

D9

Grid Location

H9

Process Capability Analysis supplier name

D10

Specific Call Out

H10

Process Capability Analysis Supplier address

J10

Name of individual responsible for GR&R study.

D11

Identification used for the feature

D12

Add additional pertinent information

J12

Name of Process Capabilty Analysis supplier contact person

C14

Date of iInstrumentation's last calibration

F14

Enter type of gage used

I14

ID of Equipment

L14

Unit of measure used

A16

Insert the name of the first operator involved in the GR&R study.

E16

Insert the name of the second operator involved in the GR&R study.

I16

Insert the name of the third operator involved in the GR&R study.

A19

Upper Spec Level

B19

Upper Spec Limit

C19

Lower Spec Limit

E19

Enter the number of trials operators conducted

H19

Total number of operators involved in study

B22

Enter 1st trial data

C22

Enter 2nd trial data

D22

Enter 3rd trial data

E22

Output is range of operator data results

F22


G22


H22


I22


J22


K22


L22


M22


A35

Gage R&R Is the Percentage of Measurement Variation (Repeatability and Reproducibility) in the Process Under 10%: Acceptable Gage 10% to 30%: May Be Acceptable Over 30%: Unacceptable and Should Be Corrected or Replaced

C37

Repeatability (Gage precision) The variation in measurements obtained with one gage when used several times by an operator while measuring the identical characteristic on the same part. Referred to as equipment variation in a Gage R&R study.

C38

Reproducibility (Operator precision) The variation in the average of the measurements made by different operators using the same gage when measuring a characteristic on one part. Referred to as Operator Variation in a Gage R&R Study.

C39

Repeatability and Reproductability

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FCD # 0427f Rev 1

Measurement Date:

Supplier Name: Part Name:Reason for Data Submission (check all that apply):

Supplier Code: Part Number Initial submission New/revised item, material or product component

Number of Cavities/Streams Drawing Number: Correction of Non-conformance New Supplier

Samples per Cavity: Revision Level: New/Revised drawing or other specification New or significantly modified process or routing

Change to optional construction or material Change of location, sub-supplier or material

Tooling: Transfer, replacement, refurbishment Other - please specify

ITEM

#

Min MaxData for Sample Number….. Sample Statistics Judgement

Comments/Action Plan

1 2 3 4 5 6 7 8 9 10 Average OK NOT OK


or additional tool.

Measurement Equipment

REQUIREMENT:Target

Bonus Applied

(Y/N) St Dev(s)

C3

Enter Supplier Name

G3

Enter Part Name from Bradley Print

T3

Indicate the reason that the data is being submitted. There may be more than one reason.

C4

Enter Supplier Code

G4

Enter Part Number from Bradley Print

C5

Enter Number of Cavities or production streams that parts are sampled from

G5

Enter the Drawing Number from Bradley print

C6

Enter the number of samples per cavity or production stream

G6

Enter Part Rev level

A11

Number Each Item. Number should match Ballon drawing

B11

Enter the measurement equipment/gage used for the Dimensional test

D11

Nominal Dimension

E11

Indicate Y/N If Bonus Was Applied

F11

Minimum acceptable value

G11

Maximum acceptable value

H11

Actual Test Values

R11

Sample statistics are calculated for directional purposes only. The sample size might not be significant to make a valid conclusion

V11

Enter Action Plan if the dimension is out of specification or needs improvement

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FCD # 0427f Rev 1

Measurement Date:

Supplier Name: Part Name:Reason for Data Submission (check all that apply):

Supplier Code: Part Number Initial submission New/revised item, material or product component

Number of Cavities/Streams Drawing Number: Correction of Non-conformance New Supplier

Samples per Cavity: Revision Level: New/Revised drawing or other specification New or significantly modified process or routing

Change to optional construction or material Change of location, sub-supplier or material

Tooling: Transfer, replacement, refurbishment Other - please specify

ITEM

#

Min MaxData for Sample Number….. Sample Statistics Judgement


1 2 3 4 5 6 7 8 9 10 Average OK NOT OK


or additional tool.


REQUIREMENT:Target

Bonus Applied

(Y/N) St Dev(s)

NOTE: Any out of specification data will require corrective action.

C3

Enter Supplier Name

G3


T3

Indicate the reason that the data is being submitted. There may be more than one reason.

C4

Enter Supplier Code

G4


C5

Enter Number of Cavities or production streams that parts are sampled from

G5


C6

Enter the number of samples per cavity or production stream

G6


A11

Number Each Item. Number should match Ballon drawing

B11

Enter the measurement equipment/gage used for the Dimensional test

D11

Nominal Dimension

E11

Indicate Y/N If Bonus Was Applied

F11

Minimum acceptable value

G11

Maximum acceptable value

H11

Actual Test Values

R11

Sample statistics are calculated for directional purposes only. The sample size might not be significant to make a valid conclusion

V11

Enter Action Plan if the dimension is out of specification or needs improvement

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FCD # 0427g Rev 1

Supplier Name Part Name:Supplier Code: Part NumberStudy Date: Drawing Number:

Revision Level:Reason For Study:

ATTACH STATISTICAL ANALYSIS PACKAGE ALONG WITH THIS FORM

Item

#

Min MaxJudgement


OK NOT OK

Initial Process Studies CTQ Verification Form


REQUIREMENT:Target

Quality Index Used

Sample Size

Quality Index Value Needs

Improvement

Prototype Pre-Production PPAP Production Issue Resolution

I4


I5


I6


I7


FCD # 0427g Rev 1

Appearance Approval ReportSupplier Name Part Name:Supplier Code: Part NumberStudy Date: Drawing Number:

Revision Level:Reason For Submission:

COLOR EVALUATION

COLOR MATERIAL TYPE MATERIAL SOURCE

TRISTIMULUS DATA GLOSS

DL* Da* Db* DE* CMC High Low

BOUNDARY SAMPLE PICTURES

Equipment Setting

Equipment Setting

Prototype Pre-Production PPAP Production Issue Resolution

I4


I5


I6


I7


A13

part color

D13

Identify first surface finish & Substrate (e.g. paint/ABS)

F13

Identify first surface and substrate suppliers (eg. Redspot/Dow)

H13

List numerical (colorimeter) data of submission part

M13

Enter loss readings in gloss units

J14

Enter Equipment Setting for Colorimeter

N14

Enter equipment setting for Glossmeter

A21

Document any Boundary Samples for Visual criteria, eg. Knit lines, sinks, etc.

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FCD # 0427h Rev 1

SAMPLE PRODUCTS

ATTACH FORM TO ALL SAMPLE PARTS OR CONTAINER PROVIDED WITH A FAIR OR PPAP SUBMISSION

SUPPLIER MANUFACTURING INFORMATION

Supplier Company Name Supplier Number

PART INFORMATION

Part Number Part Rev Part Name PO Number

No. of Cavities Samples per Cavity Total Samples

FOR BRADLEY USE ONLY

IR # (If Applicable)R&D Request # (If Applicable)PPAP # (If Applicable)

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FCD # 0427i Rev 1

Tooling Information FormSupplier Name Supplier Code Tool Location (Address)

XXXXXPart Name Part Number Part Rev

Additional Assest Numbers :

Tool Manufacturer Name Tool Manufacturer Location Number of Cavities

Note: This document must be completed for all Bradley owned tooling.

Tool InformationTool Length Tool Width Tool Height Tool Weight Tool Material

Gate Type Number of Gates Each Gate Size Nozzle Seat Radius Locator Ring Diameter

Life Expectancy (Parts) Tool Capacity per hour UCC Filing # (If Applicable) Additional Information

Press InformationPress Tonnage Actual Press Tonnage Min. Required Barrel Capacity Barrel Screw Type Press Platen size

Part Information

Shot Size Part Weight Material Alternate Material

Bradley Tool Asset Number : (If Applicable)

Material Trade Name

Alternate Material Trade Name

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FCD # 0427i Rev 1

Tool PicturesEmbed Front, Top, Back & Side View Pictures

Short Shot HistoryEmbed pictures of atleast 5 steps

Tool DrawingsEmbed or Attach all Drawings and Documentation related to the Tool Design.

Additional Comments

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FCD # 0427j Rev 1

ATTACH APPROVED WAIVER TO PARTS OR SHIPPING CONTAINER

Part Name Part No: Revision Number

Drawing or Spec No. Drawing Revision Number Bradley Plant(s) affected

Initiated By Maximum Units to be Deviated Expiration Date

Supplier Name Supplier Number

Interim Action

Corrective Action(s)Action Item Responsibility Due Date

For Bradley Use Only- Additional Comments

Product Waiver Number PWC - #XXX

Specification Waiver

Requirement Stated on Drawing or Specification

Actual Observed Results or Condition

Deviation from Specification to be Allowed

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FCD # 0427j Rev 1

Final Disposition Approve Reject

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