[XLS] · Web viewSpecification Waiver Tooling Information Form Sample Products Tag Appearance...
13
FCD # 0427a Rev 1 Part Submission Warrant Part Name Bradley Part Number Bradley Part Rev Shown on Bradley Drawing Number Drawing Rev Dated Supplier Part Number Supplier Drawing Numbe Drawing Rev Dated Safety and/or Government Regulation Purchase Order No. Weight (l 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 material Engineering Change: New/Revised drawing or other specification Change of supplier, material or non-equivalent materials/servic New process or a change in production process or method Correction of Non-conformance or discrepancy Change of manufacturing location, sub-supplier or additional lo Change to optional construction, material or component Other - please specif 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 DECLARATION I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regula process. The data and samples were produced at the production rate of in on are noted below in the explanation/comments section. #parts # hours date EXPLANATION/COMMENTS: Print Name: Job Title Phone No. Fax No. Supplier Authorized Signat 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
[XLS] · Web viewSpecification Waiver Tooling Information Form Sample Products Tag Appearance Approval Report Initial Process Studies Dimensional Test Results GR&R Multiple Control
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
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.
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:
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
Page 4 of 17
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.
Page 5 of 17
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.
Page 6 of 17
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.
Page 7 of 17
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:
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
Enter 1st trial data
G22
Enter 2nd trial data
H22
Enter 3rd trial data
I22
Output is range of operator data results
J22
Enter 1st trial data
K22
Enter 2nd trial data
L22
Enter 3rd trial data
M22
Output is range of operator data results
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
Page 9 of 17
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
Dimensional Test Results
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
Page 10 of 17
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
Dimensional Test Results
or additional tool.
Measurement Equipment
REQUIREMENT:Target
Bonus Applied
(Y/N) St Dev(s)
NOTE: Any out of specification data will require corrective action.
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
Page 11 of 17
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
Comments/Action Plan
OK NOT OK
Initial Process Studies CTQ Verification Form
Measurement Equipment
REQUIREMENT:Target
Quality Index Used
Sample Size
Quality Index Value Needs
Improvement
Prototype Pre-Production PPAP Production Issue Resolution
I4
Enter Part Name from Bradley Print
I5
Enter Part Number from Bradley Print
I6
Enter the Drawing Number from Bradley print
I7
Enter Part Rev level
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
Enter Part Name from Bradley Print
I5
Enter Part Number from Bradley Print
I6
Enter the Drawing Number from Bradley print
I7
Enter Part Rev level
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.
Page 13 of 17
FCD # 0427h Rev 1
SAMPLE PRODUCTS
ATTACH FORM TO ALL SAMPLE PARTS OR CONTAINER PROVIDED WITH A FAIR OR PPAP SUBMISSION