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APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Satisfies Schedule A Deliverable #9 / Schedule B Element #4(Special Characteristics Cascaded to Suppliers)
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Page 1 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
###
A. Program Information Date
Model Year Product Name
B. Production Supplier / Product Information
Tier 1 Supplier Name Site Code Tier 1 Supplier Location
City / Region / Country
Part Name Ford Part Number
Program Code
Engineering Change Level
New TooledEnd Item(Y/N)
Special CharacteristicsPrototype All Measurement Results
Production Process Capability Results
Production Process Control Results
Formatted to Print US (Letter/Legal)
Import Special Characteristics
APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Satisfies Schedule A Deliverable #9 / Schedule B Element #4(Special Characteristics Cascaded to Suppliers)
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Page 2 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
(PPAP Ppk = 1.67 or Production Ppk = 1.33)B30:
5 digit GSDB code for Manufacturing LocationF9:
(e.g. Red Border Notice)G27:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)G30:
(e.g. Print Revision Level)K12:
APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Satisfies Schedule A Deliverable #9 / Schedule B Element #4GPDS: Due at <PA>
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Page 3 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
Supplier Code:Part Number:
Approvers Source of Approval Evidence Name email Date
Ford Design & Release Engineer
Ford STA Engineer
Supplier Plant Quality Manager
Key: From DFMEA: From PFMEA:
YC CC
-- OS
YS SC
HI
Special Characteristic Totals: YC YS CC OS SC HINote: Auto calculation of totals 0 0 0 0 0 0
Special Characteristics Communication and Agreement
Num
ber
Characteristic Description Process Control Method1234
Ford Craftsmanship / Systems Engineering
Sev 9,10. Potential Critical Characteristic (YC)
Sev 9,10 (Part). Critical Characteristic (CC)
Sev 9,10 (Process). Operator Safety (OS)
Sev 5-8 Potential Special Characteristic (YS)
Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC)
Sev 5-8 AND Occ 4-10. High Impact Characteristic (HI)
Specification & Tolerance
DFMEA Class
(YC, YS)
PFMEA Class
(CC, OS, SC, HI)
Pass through Characteristic?
(Y/N)
Supplier's Production
Manufacturing Operation Step
Identifier
For Special Characteristic definitions refer to Ford FMEA Handbook.
APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Instructions
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 4 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
ROLES AND RESPONSIBILITIESWhat Who When
Ford Product Development (PD) GPDS: 1 month before<FDJ>
Ford PD GPDS: <PA>
Supplier GPDS: <PA>
Supplier / Ford STA / Ford PD GPDS: <PA>
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATIONTERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is releasedProgram Code
Product Name Product name is for the 'Vehicle' or 'PTO' name
B. Production Supplier / Product Information
Tier 1 Supplier Name Tier 1 Supplier responsible for the end item
Mfg. Site Code
Tier 1 Supplier Location Production manufacturing location of the Tier 1 Supplier
Part Name General name given to the end itemFord Part Number Ford designated component, sub-assembly or assembly number
New Tooled End Item (Y/N)
Drawing and Specification released to supplier (Deliverable #25)
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement Procedure (FAP 03-111)
Complete - Special Characteristics worksheet as evidence of special characteristics cascaded to suppliers (Deliverable #9)
Review Special Characteristics worksheet as evidence of special characteristics cascaded to suppliers (Deliverable #9) Note: Form FAF 03-111-2 may also demonstrate evidence of special characteristics agreement
The program code represents the Ford designation for the Vehicle or PTO program
Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits identifying the supplier manufacturing site
Engineering Change Level (e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part Print) as identified by a 4-part alphanumeric code (typically 14 characters in length) containing the following:Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern
Example: Engine NE01-E-10243645-011a) NE01 = Engineb) E = engineering releasec) 10243645 = WERS noticed) 011 = 11 Wers notices / releases attached to this concern.
Engineering Change Level - For Engineering Prototype Releases (X0, XM, M1)
Example: Engineering Prototype ReleasesGPIRS prototype release - AVTPROTO20100827- Engineering (engineering samples, xe parts ect … )CMMS prototype release - B2010EF16A252001- Material Control (components in support of engine builds prior to WERS )Is a component, sub-assembly or assembly with a new design for the given Program Code
APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Instructions
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 5 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
SPECIAL CHARACTERISTICS LISTSPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #9 / Schedule B Element #4
TERMS AND DEFINITIONSTERMS DEFINITIONS
Approvers
Ford Design & Release Engineer Ford D&R Engineer approval is mandatory per FAP 03-111
Ford STA Engineer
Ford Craftsmanship / Systems Engineering
Supplier Plant Quality Manager
Source of Approval Evidence
Characteristic Description Print specification item to be measured
Specification & Tolerance
DFMEA Classification (YS, YC)
PFMEA Classification (CC, SC, HI)
Process Control Method
Pass Through Characteristic (PTC)? (Y/N)
Supplier's Manufacturing Operation Identifier
Include all special characteristics
Ford STA Engineer approval of Process Control Methods is mandatory for external supplier manufactured parts when requested by the Ford D&R Engineer per FAP 03-111
Ford Craftsmanship / Systems Engineering approval is mandatory when requested by the Ford D&R Engineer per FAP 03-111
External Supplier Plant Quality Manager approval mandatory for external supplier manufactured parts per FAP 03-111
Identify the information source as evidence of approval. Ford Corporate Procedure FAP 03-111 requires that special characteristics approval be recorded on from FAF 03-111-2 for external manufactured parts.
Specification for the characteristic defined on the design record (print or E.S.) including the tolerance requirement
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS).
Classification as identified by the PFMEA. Other characteristics are print requirements that are not identified as Special Characteristics
How are the parts inspected or measured? If the control method is different than the method identified on the Special Characteristics Agreement then report the reasons in the Comments / Actions Taken cell.
A Pass through Characteristic (PTC) is a product characteristic whose fit or function qualities are not validated, verified or functionally tested within the manufacturing or assembly process in question (external suppliers and internally Ford-made parts). PTC are generally finished characteristics with part print Supplier's Production Manufacturing Operation identifier is a code or number unique to the operation identified on the process flow chart and process control plan
APQP/PPAP External Supplier EvidenceSpecial Characteristics
Process Flow
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 6 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Lead for activity When (VO/PTO) Input Process Output
Ford PD System design requirements
Ford PD GPDS: <PA>
Design Record
DFMEA/ PFMEA
Engineering SpecificationsFAP 03-111
Supplier GPDS: <PA>FAF 03-111-2
Priority Supplier ListProgram STA New Tooled End Item Priority Supplier
Site Readiness or Non-priority Supplier
Part Criticality
Program Induced Risk
GPDS: VP
Ongoing
GPDS: 1 month before FDJ
Drawing and Engineering Specifications
Special Char Agreement Form or FAF 03-111-2
Utilize import function macro or manual data entry
EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
Initial selection of Priority sites will
occur by Unit <PTC> /
<PTCC>+90 Days (unless otherwise
identified)
Ford PD / Site STA / Supplier
EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
Ford PD / STA / Supplier
Drawing and Specification released to supplier (Deliverable #25)
Falure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement procedure
FAP 03-111
Priority Supplier
Results maintained with APQP records
and next deliverable evidence form
Review the results of the Special Charcteristics list
during GPDS on-site visit #1
Special Charactreistics
Modified
Update External Supplier Characteristics worksheet
Yes
No
Yes
No
SPECIAL CHARACTERISTICS
DATA STORAGE AND MANAGEMENT REVIEW
Complete - Special Characteristics worksheet with special characteristics cascaded to suppliers (Deliverable #9)
APQP/PPAP External Supplier EvidenceSpecial Characteristics
Process Flow
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 7 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier Ongoing EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
Update External Supplier Characteristics worksheet
APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS
Satisfies Schedule A Deliverable #9 / Schedule B Element #4GPDS: Due at <PA>
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Page 8 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
Approvers Source of Approval Evidence Name email Date
Ford Design & Release Engineer FAF 03-111-2 John Young 1-Jun-09
Ford STA Engineer FAF 03-111-2 Ben Anderson 2-Jun-09
FAF 03-111-2 Michelle Darwin 1-Jun-09
Supplier Plant Quality Manager FAF 03-111-2 Sam Miller 15-Jun-09
Key: From DFMEA: From PFMEA:
YC CC
-- OS
YS SC
HI
Special Characteristic Totals: YC YS CC OS SC HINote: Auto calculation of totals 4 6 4 0 6 0
Special Characteristics Communication and Agreement
Num
ber
Characteristic Description Process Control Method
1 Hole size YC CC Air Gage No 10
2 Hardness 80 - 120 BHN YS SC Equotip Yes 503 Material Yield Strength 207 Mpa min YC CC tensile bars Yes 50
4 276 Mpa min YC CC tensile bars Yes 50
5 Material Elongation 7% min YC CC tensile bars Yes 506 Press - in load UCA min 29 KN YS SC Load cell Yes 407 UCA Bore diameter 10 ± 0.5 mm YS SC CMM No 308 UCA Position 0.5 mm max YS SC CMM No 309 UCA Roundness max 0.5 YS SC tallyrand No 30
10 Bushing span 7.36-7.49 mm YS SC optical comparator No 30
Ford Craftsmanship / Systems Engineering
Sev 9,10. Potential Critical Characteristic (YC)
Sev 9,10 (Part). Critical Characteristic (CC)
Sev 9,10 (Process). Operator Safety (OS)
Sev 5-8 Potential Special Characteristic (YS)
Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC)
Sev 5-8 AND Occ 4-10. High Impact Characteristic (HI)
Specification & Tolerance
DFMEA Class
PFMEA Class
Pass through Characteristic?
(Y/N)
Supplier's Production
Manufacturing Operation Step
Identifier
10.5 +/- 0.5mm
Material Ultimate Tensile Strength
For Special Characteristic definitions refer to Ford FMEA Handbook.
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Satisfies Schedule A Deliverable #23 / Schedule B Element #17GPDS: Due at <VP>
FORD PROUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 9 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier Code:Part Number:
Summary Results 1 2 3
Nu
mb
er
Characteristic Specification X-Bar Range Comments / Actions Taken
1234
DFMEA Classification
(YC, YS)
PFMEA Classification (CC, SC, HI,
Other)
On Prototype Control Plan (Y/N)
Process Control Method
Inspection Frequency
Quantity Inspected
(pcs.)
All PartsMeet
Specification(Y/N)
ActualResults
ActualResults
ActualResults
Print Cover Page &
Executive Summary
Evidence Form
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Satisfies Schedule A Deliverable #23 / Schedule B Element #17GPDS: Due at <VP>
FORD PROUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 10 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
ActualResults
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35GPDS: Due at <TT>
FORD STA Form #: PP-S-F085GIS2 Classification: Proprietary
Page 11 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
Supplier Code:
Part Number:
Characteristic Gauge R&R Process Control Distribution Analysis Capability Results
Num
ber
Characteristic Specification Actions Taken
Study Parameters
DFMEA Classification
(YC, YS)
PFMEA Classification (CC, SC, HI,
Other)
On Production
Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic
(PTC) (Y/N)
Error Proofed
(Y/N)
Process Control Method
Characteristic dependent on sub-supplier
(Include PTC)(Y/N)
Population Size
Sample Size
% Study
Variation(Target ≤ 10%)
% Tolerance(Target ≤ 10%)
Demonstrated Method of
Stability and Control
Evidence: Number of
Points Not in Control
Distribution Type
Resultant P-value or
Best Fit Coefficient
PPAP PpkValues
Production PpkValues
Meets Capability Requirement
PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33
(Y/N)
Print Cover Page &
Executive Summary Evidence
Form
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Instructions
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 12 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
ROLES AND RESPONSIBILITIESWhat Who When (Vehicle Operations) When (VP Powertrain) When (X0, XM, M1 - Powertrain Only)
GPDS: 1 month before<FDJ>
Prototype Inspection Requirements Identified Ford PD N/A
Ford PD GPDS: <PA>
Ford PD GPDS: <FDJ>
Ford PD GPDS: <FDJ>
Prototype Control Plan Completed (Deliverable #20) Supplier / Ford PD GPDS: <FDJ> uDC N/A
Produce Prototype Parts Supplier GPDS: In support of <VP> Build
Supplier GPDS: In support of <VP> Build GPDS: In support of uVP IPD
Supplier
Review the results of the Prototype Parts produced
Ford PD
Ford PD
Supplier GPDS: <VP> IDP Promise Date
Drawing and Specification released to supplier (Deliverable #25)
Ford Product Development (PD)
<uPA> to 1 month after <FDJ> based on the Plan for Every Part
Within 2 weeks after Build Phase DJ eventPO-S-25 for X0PO-T-55 for XMPO-T-70 for M1
<uPA> to <uDC>PP-U-50 for VP
<uPA> to 1 month after <FDJ> based on the Plan for Every PartPP-S-05 for X0PP-T-20 for XMPP-T-35 for M1
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
uM1DJ to uDC based on the Plan for Every Part
see terms and Definitions below for applicability per Powertrain Unit build phase
Prototype Tool Orders release to suppliers in support of Prototype Build Phase (Deliverable #21)
<uPA> to uDC based on the Plan for Every Part
Per Powertrain Unit Build phase based on the Plan for Every Part
Prototype Parts order with quantity and timing to suppliers in support of Prototype Build Phase (Deliverable #22)
<uPA> to uDC based on the Plan for Every Part
<uPA> to uDC based on the Plan for Every PartPP-S-05 for X0PP-T-20 for XMPP-T-35 for M1
GPDS: In support of uVP In Plant Date (IPD)
GPDS: In support of Powertrain Unit rough or purchased finish In Plant Date (IPD)
Conduct inspection method of Prototype Parts per Prototype Control Plan
GPDS: In support of Powertrain Unit Build Phase IPD. All required X0, XM and M1 prototype inspection is performed as agreed upon by the Product Engineer and the Supplier
Completes the EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS proforma as evidence of Deliverable #23
GPDS: Prior to shipment of <VP> Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Ford PD / Supplier Technical Assistance
(STA)
GPDS: Prior to shipment of <VP> Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Prototype Parts achieved 100% of the required print specifications identified for each build phase
GPDS: Prior to shipment of <VP> Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Any exception to the design specification requires an approved part design deviation notice (Must use e-Warrant for Powertrain. Other (e.g. WERS Alert for vehicle) prior to shipment.
GPDS: Prior to shipment of <VP> Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Supplier Ships part to meet in plant date (IPD) commitment for the Prototype Build Phase
GPDS: Supplier Promise Date must support uVP IPD
GPDS: Supplier Promise Date must support rough or finished Powertrain Unit build phase IPD(s)
Print Instructio
ns, Process
Flow, and
Examples
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Instructions
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 13 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
PROGRAM, SUPPLIER, PRODUCT, AND PROTOTYPE MANUFACTURING INFORMATION
TERMS AND DEFINITIONSTERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is releasedProgram Code The program code represents the Ford designation for the Vehicle or PTO programProduct Name Product name is for the 'Vehicle' or 'PTO' nameBuild Event The build event for the GPDS program milestone under reviewRequired In-Plant Date
Required Ford determined number of vehicles/powertrains to be built per GPDS build eventProduced Supplier number of vehicle/powertrain sets built per ford the GPDS build event
B. Production Supplier / Product Information
Tier 1 Supplier Name Tier 1 Supplier responsible for the end itemMfg. Site CodeTier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierSupplier Delivery Promise DatePart Name General name given to the end itemFord Part Number Ford designated component, sub-assembly or assembly number
New Tooled End Item (Y/N) Is a component, sub-assembly or assembly with a new design for the given Program CodeC. Prototype Manufacturing Information
Manufacturing Site Location where the end item were manufactured for the build eventCarry-over production site Same location as previous model year or common platformNew Production site New facility designated as production intent to produced the end item Prototype site
Manufacturing ProcessCarry-over process Same manufacturing process as previous model year or common platformNew production processPrototype process
Tooling TypeCarry-over production tooling Same manufacturing tooling as previous model year or common platformNew Production ToolingPrototype/ soft tooling
D. Deviations
Prototype Parts achieved 100% of the required print specifications and delivery timing
Part Deviation Notice (e.g. Red Border Notice)Quality or Timing Categorize the reason why the Ford order requirements cannot be met Engineering Notification
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENTS RESULTS PAGESPECIAL NOTES
Provide the print specifications data item by item
TERMS AND DEFINITIONS
TERMS DEFINITIONS
Characteristic (For VP Builds and beyond)Characteristic (X0, XM and M1)Specification Specification for the inspection item defined on the design record (print or E.S.)DFMEA Classification (YS, YC)PFMEA Classification (CC, SC, HI, Other)Process Control Method (VP and beyond)Process Control Method (X0, XM, and M1)On Prototype Control Plan (Y/N)Quantity Inspected (pcs.)Results: X-barResults: Range Calculates of the difference between the largest and smallest data valuesAll Parts Meet Specification (Y/N)Comments / Actions TakenData Reporting
information for the build event
The required date Ford designates all components received in-plant at the Ford designated Build Event Quantity
Planned quantity of vehicles or powertrain quantity for the Build Event. Powertrain should include internal Powertrain Dyno requirements which are not covered in vehicle build.
Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits
The date entered into GPIRS or VPP by the supplier when the end item will be received In-
Engineering Change Level (e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part Print) as identified by a 4-part alphanumeric code (typically 14 characters in length) containing the following:a) Change Level Indicator (CLI) identifying the releasing authorityEngineering Change Level - For Engineering Prototype
Releases (X0, XM, M1)CMMS manual powertrain prototype release (used by PPM) Example: B2010EF16A252001
Facility responsible for producing the end item for the specific build events (i.e. not Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing process(es) to produced the end item At least one operation contains a prototype process(es) to produced the end item for the Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing tooling to produced the end item or the At least one operation contains prototype tooling in the process utilized to produce the end item for the specific build event (i.e. not production intent)
None required, all delivered parts meet 100% of the requirements in time to support the build
A Supplier notification that they cannot meet the Ford order requirements for either quality
Provide the Deviation Notification: approved Alert number for the specification deviations. Note: North American Powertrain deviations for prototype builds prior VP are identified on the e-Warrant.
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #23 / Shedule B Element#17Report data for all required print specifications, engineering requirements and/or process characteristics. Supplier must have all information available for review. For presentations and the executive print summary to Ford management sort to put the 20 most important characteristics at the top of the completed template. Early Powertrain prototype builds (X0 - M1): Suppliers will report the results of the prototype measurements using this format to demonstrate compliance of the functional and dimensional results for the part level ordered. Ford North America Powertrain requires approved e-Warrant deviation for each characteristic that does not meet the requirements prior to shipment of the part.
All required print specification, engineering requirements and/or process characteristics All required print specification, engineering requirements and/or process characteristics as agreed upon by the Product Engineer and the Supplier are to be measured and reported on
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or Classification as identified by the PFMEA. Other characteristics are print requirements that How are the parts inspected or measured as defined in the Prototype Control Plan? If the How are the parts inspected or measured as agreed upon with the Product Engineer for Is the characteristic contained on the prototype control plan of the reporting supplier for the How many pieces are contained in the inspection results data set? Prototype part quantity Calculated average (mean) from inspection results data set. The mean (arithmetic average)
All parts measured meet the characteristic specificationMake comments specific to the inspection item and include the action plan if the inspection The supplier must complete the measurements and report for all characteristics.
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 14 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
ROLES AND RESPONSIBILITIESWhat Who When
Ford Product Development (PD) GPDS: 1 month before<FDJ>
Ford PD GPDS: <PA>
Supplier / Ford STA / Ford PD GPDS: <TT>
Supplier / Ford STA GPDS: <TT>
Supplier
Perform inspection method and collect data for analysis Supplier
Supplier
Supplier
Perform capability calculation using Ppk Formula Supplier
Supplier
Supplier / Ford STA
Supplier / Ford STA On-going
Drawing and Specification released to supplier (Deliverable #25)
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
Production Control Plan is completed and has linkages to DFMEA and PFMEA (Deliverable #20)
Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
Conduct a valid production trial run(s) per the Phase PPAP requirements. Phase 0 PPAP occurs at TT Build (Deliverable #36) and Phase II PPAP occurs at PP Build (Deliverable #42) for GPDS.
GPDS: <TT> andGPDS: <PP>
GPDS: <TT> andGPDS: <PP>
Analyze data set for statistical process control of the specified special characteristics
GPDS: <TT> andGPDS: <PP>
Analyze the data set for normality (normal distribution) of the specified special characteristics
GPDS: <TT> andGPDS: <PP>
GPDS: <TT> andGPDS: <PP>
Completes the EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS proforma
GPDS: <TT> andGPDS: <PP> and as requested
Initial process capability results (Ppk) have achieved results ≥1.67
GPDS: <TT> andGPDS: <PP>
Production process capability results (Ppk) have achieved results ≥ 1.33
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 15 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATIONTERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is released
Program Code
Product Name Product name is for the 'Vehicle' or 'PTO' name
Build Event The build event for the GPDS program milestone under review
B. Production Supplier / Product Information
Tier 1 Supplier Name Tier 1 Supplier responsible for the end item
Mfg. Site Code
Tier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierPhase PPAP Status:
Promise Date
PPAP Approval Date Completed PPAP approval for the Phase PPAP DeliverablesPart Name General name given to the end item
Ford Part Number Ford designated component, sub-assembly or assembly number
New Tooled End Item (Y/N)
C. Manufacturing Information
Manufacturing Site Location where the end item is manufactured for the build event
Carry-over production site Same location as previous model year or common platform
New Production site New facility designated as production intent to produce the end item
Prototype site
Manufacturing Process
Carry-over process Same manufacturing process as previous model year or common platform
New process
The program code represents the Ford designation for the Vehicle or PTO program
Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits identifying the supplier manufacturing site
The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables
Promise date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables
Engineering Change Level (e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part Print) as identified by a 4-part alphanumeric code (typically 14 characters in length) containing the following:a) Change Level Indicator (CLI) identifying the releasing authorityb) Part drawing revision letter (single letter)c) Electronic Release System code (WERS = 8-digit concern number)d) Release Status of the part in the electronic release system (WERS = 3-digit increments of any notices attached to the part)Engineering Change Level is also reported on the PSW.
Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern
Is the component, sub-assembly or assembly a new design for the given Program Code?
Facility responsible for producing the end item for the specific build events (i.e. not production intent)
Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing process(es) to produced the end item for the specific build event (i.e. production intent process)
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 16 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Prototype process
Tooling Type
Carry-over tooling Same manufacturing tooling as previous model year or common platform
New Production Tooling
Prototype/ soft tooling
Process Capability Data Represent
One Production Stream
All Production Streams
D. Deviations
Engineering notification
At least one operation contains a prototype process(es) to produced the end item for the specific build event
Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing tooling to produced the end item or the specific build event (i.e. production intent process)
At least one operation contains prototype tooling in the process utilized to produce the end item for the specific build event (i.e. not production intent)
Demonstrate that Initial Process Capability studies have been completed using Run-at-Rate parts from the same production stream
Demonstrate that separate Initial Process Capability studies have been completed using Run-at-Rate parts from each production stream.
None required, production process is capable (PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33)
Parts achieved PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33 from the production streams studied
Action taken for non-capable process (PPAP Ppk < 1.67 or Production Ppk < 1.33)
The modified control method shall include techniques to incorporate mistake proofing methods into the manufacturing process to prevent the shipment of non compliant product to Ford facilities.Note: examples of mistake proofing methods include the modification of manufacturing processes to detect and discard non compliant product (e.g., poke-yoke), or a gauge to ensure product compliance to specification where the process does not meet the capability requirements. This is not the addition of a temporary manual inspection process at the end of the line.
Provide the Deviation Notification. Example: approved WERS Alert number for the specification deviations with the interim PPAP submission.
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 17 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGESPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Element #35
When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days TERMS AND DEFINITIONS
TERMS DEFINITIONS
Characteristic Print specification item to be measured
Specification Specification for the characteristic defined on the design record (print or E.S.)
DFMEA Classification (YS, YC)
PFMEA Classification (CC, SC, HI, Other)
On Production Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Study Parameters
Population What is the population (or estimate) size that contains the samples?
Sample Size How many pieces are contained in the inspection results data set?
Gauge R&R Repeatability and reproducibility of the measuring system
% Study Variation
% Tolerance Measurement Error as a percentage of Tolerance
Demonstrated Method of Stability and Control
Include all special characteristics
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS).
Classification as identified by the PFMEA. Other characteristics are print requirements that are not identified as Special Characteristics
Is the characteristic contained on the production control plan of the reporting supplier?
Supplier's Production Manufacturing Operation identifier is a code or number unique to the operation identified on the process flow chart and process control plan
A Pass through Characteristic (PTC) is a product characteristic whose fit or function qualities are not validated, verified or functionally tested within the manufacturing or assembly process in question (external suppliers and internally Ford-made parts). PTC are generally finished characteristics with part print tolerances or specifications that are not verified in house or at the supplier, and where defective parts can be passed on to the customer (defined as Vehicle Operations or the buying public).Examples may include:Engine ThermostatsTorque Converter studsCylinder Head – FEAD mounting holesTransmission Case – Starter mounting holesThreaded hole supplied by an external supplier, not used in Powertrain Plant
Does the characteristic have an error proof method? This is required for CCs and Ford identified PTCs.
How are the parts inspected or measured? If the control method is different than the method identified on the Special Characteristics Agreement then report the reasons in the Comments / Actions Taken cell.
Characteristic dependent on sub-supplier (Include PTC)(Y/N)
Does the characteristic control require process control at a sub-supplier? This applies to all characteristics classifications and include PTCs.
Study parameters refers to the sample size and population where the capability study data is collected
Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)
Identify the method of statistical process control evaluation. Statistical process control evaluation techniques include X-bar and R, or X-bar and S, or I-MR. Note: For charting, X-bar and R or X- bar and S, 25 subgroups of 3 to 5 pcs
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 18 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Evidence: Number of Points Not in Control
Distribution Analysis
Distribution Type
Resultant P-value or Best Fit Coefficient
Results: PPAP Ppk or Production Ppk
Where standard deviation is defined as:
Comments / Action TakenData Reporting
Report the number of data points not in control. Out of control coniditions occur when there is data outside the control limits. An out of control condition for the X-bar chart is defined as 1 point greater or less than 3 standard deviations from the mean. If more that 1 data point is not in-control then action is required.
The data distribution needs to be evaluated and identified for the appropriate capability analysis calculation. For example, a normal distribution test requires a P-value greater than 0.05 to assume normality. Non-normal data requires data transformation
Select the type of distribution identified for the capability analysis. Refer to a known distributions based on the physics or specific types of process available through your STA engineer.
Report the distribution fit statistical hypothesis p-value or the best fit coefficient from the distribution identification fit technique as appropriate
Process Capability Formula: Ppk Example below is a calculation for a normal distribution(Other capability distribution calculations may be applied where appropriate per ISO 21747)
Meets Capability RequirementPPAP Ppk ≥ 1.67Production Ppk ≥ 1.33 (Y/N)
Conditional formatting will automatically populate the cell based on the process capability results meeting the PPAP Ppk requirement or the Production Ppk requirements. PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33 Note: Capability can NOT be determined until tConditional formatting will identify through field transition to clear when comments for action taken is needed based on meeting the capability The supplier must complete the measurements and report for all special characteristics. The first 20 characteristics are selected for report out to Ford management
Ppk=min(USL−X )
3 σ̂ S or
( X−LSL )3 σ̂ S
Ppk: { σ̂ S=√∑i=1
n (X i−X )2
n−1¿
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Process Flow
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 19 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Lead for activity When (VO/PTO) Input Process Output
Ford PD System design requirements
Ford PD GPDS: <PA>
Design Record
DFMEA
Engineering SpecificationsFAP 03-111
Ford PD GPDS: FDJ Program requirements Prototype Tool Order
Ford PD GPDS: FDJ Program requirements
Supplier / Ford PD GPDS: FDJ
Prototype Control Plan
Supplier
Supplier
Supplier X-Bar
Range
GPDS: 1 month before FDJ
Drawing and Engineering Specifications
Special Char Agreement Form or FAF 03-111-2
Prototype Parts Order: quantity and timing
Prototype Parts Order: quantity and timing
Including process parameter, gauges, inspection methods, tolerances, reaction plan(s) in the Control Plan.
Special Char Agreement (FAF 03-111-2)
GPDS: In support of VP Build
GPDS: In support of VP Build
Verify that gauges and test equipment are accurate, repeatable, and reproducible with adequate discrimination
Prototype part inspection and measurement data
GPDS: In support of VP Build
Prototype part inspection and measurement data
Prototype part inspection and measurement data
Drawing and Specification released to supplier (Deliverable #25)
Falure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement within this
workbook or FAF 03-111-2
Prototype Tool Orders release to suppliers in support of Verification Prototype (VP) Build
(Deliverable #21)
Prototype Parts order with quantity and timing to suppliers in support of VP Build
(Deliverable #22)
Prototype Control Plan Completed (Deliverable #20)
Quantity Inspected (pcs)Corrective action for non-conformancing
product
PROTOTYPE CONTROL PLAN
X-Bar
Range
RESULTS
PRODUCE PROTOYPE PARTS
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Process Flow
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 20 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier
Priority Supplier ListProgram STA New Tooled End Item Priority Supplier
Site Readiness or Non-priority Supplier
Part Criticality
Program Induced Risk
Ford PD
Supplier
GPDS: Prior to shipment of parts
for VP MRD
Prototype part inspection and measurement data
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS proforma
Include COMMENTS / ACTIONS TAKEN when all parts do not meet specification for the given characteristic
Initial selection of Priority sites will
occurPTO - 2months before Unit PTC
UN - PTCCUP - PTC/M-1DJ (unless otherwise
identified)
Ford PD /Supplier Technical Assistance
GPDS: Prior to shipment of parts
for VP MRD
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS with team input
GPDS: Prior to shipment of parts
for VP MRD
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
Agreement to ship the prototype parts
Any exception to the design specification requires an approved part design deviation notice (e.g. WERS Alert) prior to shipment.
GPDS: Prior to shipment of parts
for VP MRD
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
Completed EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
Prototype Parts achieved 100% of the required print specifications.
Review the results of the Prototype Parts produced during GPDS on-
site visit #2
YesYes
Update evidence form updated with Alert Number
No Ford PD Approves part deviation notice
No
PROTOTYPE DATA REVIEW
Range
Priority Supplier
Yes
No
Completes the EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS proforma as evidence of Deliverable #23
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Process Flow
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 21 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier GPDS: VP MRD
Priority Supplier ListProgram STA New Tooled End Item Priority Supplier
Site Readiness or Non-priority Supplier
Part Criticality
Program Induced Risk
Ford PD / Site STAGPDS: VP
Program STAGPDS: VP
Site STA GPDS: VP
Site STAGPDS: VP
Ford ManagementGPDS: VP
Agreement to ship the prototype parts
Initial selection of Priority sites will
occur by Unit <PTC> /
<PTCC>+90 Days (unless otherwise
identified)
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS
Sort data into top 20 most important characteristics(e.g. importance to part functionality)
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS (Top 20 Characteristics)
Functional area requested supplier proformas
Functional area EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
All functional area requested supplier proformas All functional area EXTERNAL
SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
Suppler Ships part to meet in plant date (IDP) commitment for VP Build
Priority Supplier
Results maintained with APQP records
Review the results of the Prototype Parts produced
during GPDS on-site visit #2
Program ReviewRequested
Select 'Print Cover Page & Executive Summary Evidence
Form' button to print top 20 characteristics
Send file to STA Program team
Yes
No
Ford Management review of data & feed back actions to STA
Engineer
Yes
No
DATA STORAGE AND MANAGEMENT REVIEW
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Satisfies Schedule A Deliverable #23 / Schedule B Element #17(Prototype parts Achieved 100% of Required Print Specifications)
FORD PRODUCT DEVELOPMENTForm #:PP-S-F085GIS2 Classification: Proprietary
Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
###A. Program Information Date 13-Jul-09
Model Year Product Name Build Event2011 U502 Explorer VP 17-Jul-09 17-Aug-09 Required 94
Produced 150
B. Production Supplier / Product Information
Tier 1 Supplier Name Site Code Tier 1 Supplier LocationCMI - Muskegon U044M Muskegon, MI USA
City / Region / Country
Part Name Ford Part Number
REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y
C. Manufacturing Information
Manufacturing Site Manufacturing Process Tooling Type
Carry-over production site CMI - Muskegon Carry-over production process Carry-over production tooling
New production site New production process New production tooling
Prototype site Prototype process Prototype / soft tooling
D. Deviations
Prototype / All Measurement Results Reason Alert #
Timing
Quality or Timing
Program Code
Required In-Plant
Date
Supplier Delivery Promise
DateBuild Event
Quantity
Engineering Change Level
New TooledEnd Item (Y/N)
Check One
Check One
Check One
None required, all delivered parts meet 100% of the requirements in time to support the build
Part Deviation Notice
Engineering Notification
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Satisfies Schedule A Deliverable #23 / Schedule B Element #17(Prototype parts Achieved 100% of Required Print Specifications)
FORD PRODUCT DEVELOPMENTForm #:PP-S-F085GIS2 Classification: Proprietary
Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
(PPAP Ppk = 1.67 or Production Ppk = 1.33)B30:
5 digit GSDB code for Manufacturing LocationF9:
(e.g. Red Border Notice)G27:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)G30:
(e.g. Print Revision Level)K12:
APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS
Satisfies Schedule A Deliverable #23 / Schedule B Element #17 GPDS: Due at <VP>
FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary
Page 24 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Num
ber
Characteristic Specification
Results
Comments / Action PlanX-Bar Range
1 Material Yield Strength YC CC 207 Mpa min tensile bars Y 4 218 3 Y none required
2 YC CC 276 Mpa min tensile bars Y 4 290 10 Y none required
3 Material Elongation YC CC 7% min tensile bars Y 4 11 2 Y none required
4 Press - in load UCA YS SC min 29 KN Load cell Y 150 35 KN 5 KN Y none required
5 UCA Bore diameter YS SC 10 ± 0.5 mm CMM Y 150 10.2 0.2 Y none required
6 UCA Position YS SC 0.5 mm max CMM Y 150 0.75 0.25 Y none required
7 UCA Roundness YS SC max 0.5 tallyrand Y 150 0.22 0.4 Y none required
8 Bushing span YS SC 7.36-7.49 mm optical comparator Y 150 7.44 0.04 Y none required
9 Shield diameter other 19.0 +0.2 / -0.1 CMM Y 150 18.99 0.14 Y none required
10 other 9.2 +0.1/-0.2 Caliper Y 150 9.17 0.24 Y none required
11 other 14.6 ± .1 CMM Y 150 14.61 0.03 Y none required
12 Side support length other 17.2±0.1 Caliper Y 150 17.26 0.08 Y none required
13 Stud torque other 4.5-6.3 Nm torque meter Y 150 5.1 0.2 Y none required
14 RD Can base other 166.23±2.5 CMM Y 150 165.91 2.58 Y none required
15 Outlet block height other 49.0±2.5 Caliper Y 150 47.56 1.27 Y none required
16 Leak check other max 7 ccm Helium leak detector Y 150 2.2 1.9 Y none required
17 Hydralic Pressure other 1200 -1400 PSI Dial Gage Y 150 1300 250 Y none required
18 Valve torque other 1-6 lb-in torque meter Y 150 3.1 1.5 Y none required
19 Valve height other 6.1-7.1mm Dial Gauge Y 150 6.5 0.75 Y none required
20 Cap torque other 2-12 lb-in torque meter Y 150 7.5 2.6 Y none required
DFMEA Classification
(YC, YS)
PFMEA Characteristic Classification (CC, SC, HI,
Other)
Inspection Method
On Prototype
Control Plan (Y/N)
Quantity Inspected
(pcs.)
All PartsMeet Specification
(Y/N)
Material Ultimate Tensile Strength
Inside side support dimensionBearing bolt hole diameter
External Supplier Submissions: Report all print requirements. Add rows as necessary.Internal Ford Usage Note: Characteristics #21 and beyond are on file with the supplier
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Process Flow
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 25 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
When (VO/PTO) Input Process Output
Characteristics isted
Specificaiton limits
Ford PD GPDS: <PA>DFMEA Characteristic Classification
DFMEA PFMEA Characteristic Classification
PFMEA
Ford PD Production Control Plan Linkage
Manufacturing Operation Identifier
Pass through characteristics identified Error Proof methods
Inspection methods and gauges
Run-at-rate
Parts available for measurement
Capacity Analysis Report (CAR)
Lead for activity
Ford Product Development
GPDS: 1 month before FDJ Drawing and Specification released to
supplier (Deliverable #25)
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement within this workbook or FAF 03-111-2
GPDS: TT / Unit <TT>
Production Control Plan is completed and has linkages to DFMEA and PFMEA (Deliverable #37)
Supplier / Ford STA
GPDS: TT / Unit <TT>
Supplier / Ford STA / Ford PD
GPDS: TT / Unit <TT>
Inspection methods, gauges, and test equipment
Supplier / Ford STA / Ford PD
GPDS: TT / Unit <TT>
Sub-supplier process flow / PFMEA / control plan
Sub-supplier control plan contains process control methods
Supplier / Ford STA
Phase 0: Prior to TT MRD/Unit <TT> MRD (VO/PTO) and Phase II: PP MRD/Unit <PP> MRD (VO/PTO)
Conduct a valid production trial run(s) per the Phase PPAP requirements. (i.e. Run-at-Rate completed on production homeline equipment, process, and tooling)
Phase 0 (Deliverable #36) and Phase II (Deliverable #42) for GPDS.
Supplier / Ford STA
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
Measurement System Analysis - Gauge R&R Measurement System Analysis
Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
Characteristic and Specification
DFMEA and PFMEA Characteristic Classification
(CC, SC, HI, Other)
%Study Variation
Pass Through Characteristic (PTC) and Error Proofed
Remove special causes and
implement corrective actions
On Production Control Plan (Y/N) and Manufacturing Operation Identifier
Process control method
Population Size
CHARACTERISTICS
GAUGE R&R
Sample Size
%Tolerance
Characteristic dependent on sub-supplier (Include PTC)
STUDY PARAMETERS
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Process Flow
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 26 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier
SupplierStatistical software (e.g. MINITAB)
Normality tests
Distribution TypeResultant P-Value
Distribution ID fit statistical analysis
Known Distribution List
SupplierStatistical software (e.g. MINITAB)
Ppk calculation
SupplierStatistical software (e.g. MINITAB)
Ppk calculation Meets PPAP Ppk of 1.67
Or Action Taken
Meets Production Ppk of 1.33Or Action Taken
SupplierStatistical software (e.g. MINITAB)Ppk calculation
(Post PPAP)
Supplier
Stable and in-control statistical process control tools (Xbar and R or Xbar and S, or IM-R or other method)
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
Statistical process control tools (Xbar and R or Xbar and S, or IM-R or other method)
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
Data transformation method (Box-Cox or Johnson Transformations) as needed
Best Fit Coefficient for alternative distributions
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
PPAP Ppk requirement OR Production Ppk requirementPending PPAP or PPAP previously
achieved
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
On going production
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
Completed EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
Include ACTIONS TAKEN when capability requirements for the given characteristic are not met
Yes
Evidence demonstrates stability & control
Data is normally distributed
DISTRIBUTION ANALYSIS
Known Distribution ID
Fit
No
Perform capability calculationusing Ppk Formula
PPAP Ppk process capability meets 1.67 Requirement
Production Ppk process capability meets 1.33 Requirement
Mistake-proof modified control method is in place if the process capability does not
meet the requirements
Identified special cause remove from data set
PROCESS CONTROL
No
Yes
Yes
No
Yes
No
CAPABILITY RESULTS
YesNo
No
Yes
No
Yes
Non-normal data is
transformed
No
Yes
Capability Study is evidence for PPAP
Report results on EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS proforma
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Process Flow
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 27 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Priority Supplier ListNew Tooled End Item Priority Supplier Site Readiness Non-priority SupplierPart Criticality
Program STA Program Induced Risk
Site STA
Ford PD
Program STA Programs request supplier proformas
SupplierPrograms request supplier proformas
Site STA
MP1 + 90 DAYS As requested by Ford Program
Initial selection of Priority sites will
occurPTO - 2months before Unit PTC
UN - PTCCUP - PTC/M-1DJ (unless otherwise
identified)
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
Conduct a valid production trial run(s) per the Phase PPAP requirements. (i.e. Run-at-Rate completed on production homeline equipment, process, and tooling)
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
Sort data into top 20 most important characteristics(e.g. importance to part functionality)
Functional area EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS (sort Top 20)
Ford Management
GPDS: TT / Unit <TT> and
GPDS: PP MRD / Unit <PP> MRD
All functional area requested supplier proformas All functional areas\ EXTERNAL
SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
Supplier / Site STA
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
Priority Supplier
File results in support of PPAP
Results review during GPDS on-site Visit #3 and Visit #4
Program Review
Requested
Send file to STA Program team as requested
Select 'Print Cover Page & Executive Summary Evidence Form' button to
print top 20 characteristics
Yes
No
Ford Management review of data & feed back actions to STA Engineer
Yes
No
DATA STORAGE AND MANAGEMENT REVIEW
When specified by Ford, submit completed process control capability evidence
ONGOING PRODUCTION CONTROL VERIFICATION
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35(Initial Process Capability Results (Ppk) >= 1.67)
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
###A. Program Information Date 5-Aug-09
Model Year Product Name Build Event2010 B299N Fiesta TT
Phase PPAP Status
B. Production Supplier / Product Information Phase 1 Phase 2 Phase 3
Tier 1 Supplier Name Site Code Tier 1 Supplier Location Promise Date 10-Aug-10 1-Oct-10 20-Dec-09
CMI - Muskegon U044M Muskegon, MI USA PPAP Approved Date 4-Aug-09City / Region / Country
Part Name Ford Part Number
REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y
C. Manufacturing Information
Manufacturing Site Manufacturing Process Tooling Type
Carry-over production site CMI - Muskegon Carry-over production process Carry-over production tooling
New production site New production process New production tooling
Prototype site Prototype process Prototype / soft tooling
One production stream
All production streams
D. Deviations
Process Capability Results Alert #
Actions taken for non-capable process(See page 2 for Actions Taken)
Program Code
Engineering Change Level
New TooledEnd Item (Y/N)
Check One
Check One
Check One
Process Capability Data Represent:
None required, production process is capable
Engineering notification
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35(Initial Process Capability Results (Ppk) >= 1.67)
FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary
Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
(PPAP Ppk = 1.67 or Production Ppk = 1.33)B30:
5 digit GSDB code for Manufacturing LocationF9:
(e.g. Red Border Notice)G27:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)G30:
(e.g. Print Revision Level)K12:
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35GPDS: Due at <TT>
FORD STA Form #: PP-S-F085GIS2 Classification: Proprietary
Page 30 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Characteristic Gauge R&R Process Control Capability Results
Num
ber
Characteristic Specification Actions Taken
1 Hole size 10.5 +/- 0.5mm YC CC Y OP10 N Y Air Gage N 300 125 10.54% 9.55% X-bar and R 1 N 100% in-line air gage
2 Hardness 80 - 120 BHN YS SC Y Subsupplier Y N Equotip Y 300 30 18.66% 3.33% I-MR 0 Normal 0.06 1.68 Y
3 207 Mpa min YC CC Y Subsupplier Y N tensile bars Y 300 30 2.09% 2.22% I-MR 0 Normal 0.76 2.01 Y
4 276 Mpa min YC CC Y Subsupplier Y N tensile bars Y 300 30 3.45% 2.77% I-MR 0 Weibull 0.88 1.77 Y
5 Material Elongation 7% min YC CC Y Subsupplier Y N tensile bars Y 300 30 9.09% 4.67% I-MR 0 Weibull 0.06 1.88 Y
6 Press - in load UCA min 29 KN YS SC Y OP40 N Y Load cell N 300 125 2.55% 5.99% X-bar and R 2 N
7 UCA Bore diameter 10 ± 0.5 mm YS SC Y OP20 N Y CMM N 300 125 12.45% 11.11% X-bar and R 0 0.002 1.67 Y
8 UCA Position 0.5 mm max YS SC Y OP20 N N CMM N 300 125 18.56% 15.88% X-bar and R 0 Lognormal 0.85 1.81 Y
9 UCA Roundness max 0.5 YS SC Y OP30 N Y tallyrand N 300 125 21.50% 17.76% X-bar and R 0 0.001 1.34 N 100% in-line air gage
10 Bushing span 7.36-7.49 mm YS SC Y OP20 N N optical comparator Y 300 125 4.65% 7.88% X-bar and R 0 Normal 0.34 2.33 Y
Study Parameters
Distribution Analysis
DFMEA Classification
(YC, YS)
PFMEA Classification (CC, SC, HI,
Other)
On Production
Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic
(PTC) (Y/N)
Error Proofed
(Y/N)
Process Control Method
Characteristic dependent on sub-supplier
(Include PTC)(Y/N)
Population Size
Sample Size
% Study
Variation(Target ≤ 10%)
% Tolerance(Target ≤ 10%)
Demonstrated Method of
Stability and Control
Evidence: Number of
Points Not in Control
Distribution Type
Resultant P-value or
Best Fit Coefficient
PPAP PpkValues
Production PpkValues
Meets Capability Requirement
PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33
(Y/N)
Material Yield Strength
Material Ultimate Tensile Strength
100% press force monitoring
Box-Cox Transformed
Johnson Transformed
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS
Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)GPDS: MP1 to MP1 + 90 Days
FORD STA Form #: PP-S-F085GIS2 Classification: Proprietary
Page 31 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
Supplier Code:
Part Number:
Characteristic Gauge R&R Process Control
Num
ber
Characteristic Specification Actions Taken
1
2
3
4
Study Parameters
DFMEA Classification
(YC, YS)
PFMEA Classification (CC, SC, HI,
Other)
On Production
Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic
(PTC) (Y/N)
Error Proofed
(Y/N)
Process Control Method
Characteristic dependent on sub-supplier
(Include PTC)(Y/N)
Population Size
Sample Size
% Study
Variation(Target ≤ 10%)
% Tolerance (Target ≤ 10%)
Demonstrated Method of
Stability and Control
Evidence: Number of
Points Not in Control
Print Cover Page & Executive Summary
Evidence Form
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 32 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
ROLES AND RESPONSIBILITIESWhat Who When
Ford Product Development (PD) GPDS: 1 month before<FDJ>
Ford PD GPDS: <PA>
Supplier / Ford STA / Ford PD GPDS: <TT>
Supplier / Ford STA GPDS: <TT>
Supplier On-going
Supplier Weekly from MP1 to MP1 + 90 days
Supplier / Ford STA On-going
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATIONTERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is released
Program Code
Product Name Product name is for the 'Vehicle' or 'PTO' name
Build Event The build event for the GPDS program milestone under review
B. Production Supplier / Product Information
Tier 1 Supplier Name Tier 1 Supplier responsible for the end item
Mfg. Site Code
Tier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierPhase PPAP Status:
Promise Date
PPAP Approval Date Completed PPAP approval for the Phase PPAP DeliverablesPart Name General name given to the end item
Ford Part Number Ford designated component, sub-assembly or assembly number
New Tooled End Item (Y/N)
C. Manufacturing Information
Manufacturing Site Location where the end item is manufactured for the build event
Carry-over production site Same location as previous model year or common platform
Drawing and Specification released to supplier (Deliverable #25)
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
Production Control Plan is completed and has linkages to DFMEA and PFMEA (Deliverable #20)
Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
Execute control plan and monitor process for statistical process control
Report process control results on the EXTERNAL SUPPLIER PRODUCTION PROCESS CONTROL RESULTS proforma
All production processes are stable and in-control; actions taken for out of control processes
The program code represents the Ford designation for the Vehicle or PTO program
Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits identifying the supplier manufacturing site
The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables
Promise date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables
Engineering Change Level (e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part Print) as identified by a 4-part alphanumeric code (typically 14 characters in length) containing the following:Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern
Is the component, sub-assembly or assembly a new design for the given Program Code?
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 33 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
New Production site New facility designated as production intent to produce the end item
Prototype site
Manufacturing Process
Carry-over process Same manufacturing process as previous model year or common platform
New process
Prototype process
Tooling Type
Carry-over tooling Same manufacturing tooling as previous model year or common platform
New Production Tooling
Prototype/ soft tooling
Process Capability Data Represent
One Production Stream
All Production Streams
D. Deviations
Actions taken for out of control processes
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGESPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Row #35
When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days TERMS AND DEFINITIONS
TERMS DEFINITIONS
Characteristic Print specification item to be measured
Specification Specification for the characteristic defined on the design record (print or E.S.)
Facility responsible for producing the end item for the specific build events (i.e. not production intent)
Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing process(es) to produced the end item for the specific build event (i.e. production intent process)
At least one operation contains a prototype process(es) to produced the end item for the specific build event
Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only
At least one operation contains new manufacturing tooling to produced the end item or the specific build event (i.e. production intent process)
At least one operation contains prototype tooling in the process utilized to produce the end item for the specific build event (i.e. not production intent)
Demonstrate that Initial Process Capability studies have been completed using Run-at-Rate parts from the same production stream
Demonstrate that separate Initial Process Capability studies have been completed using Run-at-Rate parts from each production stream.
All production processes are stable and in-control Demonstrated method of stability and control evidence indicates all points are in control
The modified control method shall include techniques to incorporate mistake proofing methods into the manufacturing process to prevent the shipment of non compliant product to Ford facilities.Note: examples of mistake proofing methods include the modification of manufacturing processes to detect and discard non compliant product (e.g., poke-yoke), or a gauge to ensure product compliance to specification where the process does not meet the capability requirements. This is not the addition of a temporary manual inspection process at the end of the line.
FTTPlannedDemonstrated
Report the manufacturing process First Time Through (FTT) as a planned (target) and demonstrated (actual) result. FTT is the percentage of units processed at the Evaluation Point (EP) that meet Quality Guidelines the first time without being repaired, retested, returned from within the plant, or scrapped.
Include all special characteristics
Total Units Processed - Units Not OKTotal Units Processed
FTT @ an EP = X 100 %
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS
Instructions
FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary
Page 34 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010
Version 1
DFMEA Classification (YS, YC)
PFMEA Classification (CC, SC, HI, Other)
On Production Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Study Parameters
Population What is the population (or estimate) size that contains the samples?
Sample Size How many pieces are contained in the inspection results data set?
Gauge R&R Repeatability and reproducibility of the measuring system
% Study Variation
% Tolerance Measurement Error as a percentage of Tolerance
Demonstrated Method of Stability and Control
Evidence: Number of Points Not in Control
Comments / Action Taken
Data Reporting
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS).
Classification as identified by the PFMEA. Other characteristics are print requirements that are not identified as Special Characteristics
Is the characteristic contained on the production control plan of the reporting supplier?
Supplier's Production Manufacturing Operation identifier is a code or number unique to the operation identified on the process flow chart and process control plan
A Pass through Characteristic (PTC) is a product characteristic whose fit or function qualities are not validated, verified or functionally tested within the manufacturing or assembly process in question (external suppliers and internally Ford-made parts)
Does the characteristic have an error proof method? This is required for CCs and Ford identified PTCs.
How are the parts inspected or measured? If the control method is different than the method identified on the Special Characteristics Agreement then report the reasons in the Comments / Actions Taken cell.
Characteristic dependent on sub-supplier (Include PTC)(Y/N)
Does the characteristic control require process control at a sub-supplier? This applies to all characteristics classifications and include PTCs.
Study parameters refers to the sample size and population where the capability study data is collected
Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)
Identify the method of statistical process control evaluation. Statistical process control evaluation techniques include X-bar and R, or X-bar and S, or I-MR. Note: For charting, X-bar and R or X- bar and S, 25 subgroups of 3 to 5 pcs
Report the number of data points not in control. Out of control coniditions occur when there is data outside the control limits. An out of control condition for the X-bar chart is defined as 1 point greater or less than 3 standard deviations from the mean. If more that 1 data point is not in-control then action is required.
Conditional formatting will identify through field transition to clear when comments for action taken is needed based on demonstration of process control. Make comments specific to the special characteristic and include actions taken for out of control process.
The supplier must complete the measurements and report for all special characteristics.
APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS
Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)GPDS: MP1 to MP1 + 90 Days
FORD STA Form #: PP-S-F085GIS2 Classification: Proprietary
Page 35 of 35Date Issued: 14-Jul-2009
Date Revised: 22-Sep-2010Version 1
Characteristic Gauge R&R Process Control
Num
ber
Characteristic Specification Actions Taken
1 Hole size 10.5 +/- 0.5mm YC CC Y 10 Y Y Air Gage N 300 125 10.54% 9.55% X-bar and R 1
2 Hardness 80 - 120 BHN YS SC Y 50 Y N Equotip Y 300 30 18.66% 3.33% I-MR 0
3 207 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 2.09% 2.22% X-bar and R 0
4 276 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 3.45% 2.77% Other 0
5 Material Elongation 7% min YC CC Y 50 Y N tensile bars Y 300 30 9.09% 4.67% I-MR 0
6 Press - in load UCA min 29 KN YS SC Y 40 Y Y Load cell Y 300 125 2.55% 5.99% X-bar and R 2
7 UCA Bore diameter 10 ± 0.5 mm YS SC Y 30 N N CMM N 300 125 12.45% 11.11% X-bar and R 0
8 UCA Position 0.5 mm max YS SC Y 30 N N CMM N 300 125 18.56% 15.88% 3
9 UCA Roundness max 0.5 YS SC Y 30 N N tallyrand N 300 125 21.50% 17.76% 4
10 Bushing span 7.36-7.49 mm YS SC Y 30 N N optical comparator N 300 125 4.65% 7.88% X-bar and S 0
Study Parameters
DFMEA Classification
(YC, YS)
PFMEA Classification (CC, SC, HI,
Other)
On Production
Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic
(PTC) (Y/N)
Error Proofed
(Y/N)
Process Control Method
Characteristic dependent on sub-supplier
(Include PTC)(Y/N)
Population Size
Sample Size
% Study
Variation(Target ≤ 10%)
% Tolerance (Target ≤ 10%)
Demonstrated Method of
Stability and Control
Evidence: Number of
Points Not in Control
Air gage is 100% inspection frequency
Material Yield Strength
Material Ultimate Tensile Strength
Load cell is 100% inspection frequency
End Point Control
Containment of suspect lot 100% re-inspected
Modified Control Chart
for Non Random Variation
Air gage is 100% inspection frequency