APQP/PPAP

WORKBOOK V4b
Copyright © 2006 March Quality Services

Part Name NAME

Part Number NUMBER
Engineering Change Level ECL
Engineering Change Level Date ECL DATE

Organization Name ORGANIZATION

Organization Code CODE
Street Address ADDRESS
City CITY
State STATE
Zip ZIP
Phone Number 555-555-5555

Customer Name GM
Division DIVISION
Application APPLICATION

File Name FILE.XLS

For sales and technical support contact AIAG at 1-248-358-3570

THE FOLLOWING LEVELS OF DOCUMENTS WERE USED TO PREPARE THIS WORKBOOK.

DOCUMENT EDITION PRINTING

ADVANCED PRODUCT QUALITY PLANNING AND CONTROL PLAN First Feb-95
REFERENCE MANUAL
MEASUREMENT SYSTEM ANALYSIS Third Mar-02
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Third Jul-01
PRODUCTION PART APPROVAL Fourth Mar-06
 A-1 DESIGN FMEA CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Was the SFMEA and/or DFMEA prepared using
the DaimlerChrysler, Ford, and General Motors
Potential Failure Mode and Effects Analysis
(FMEA) reference manual?
2 Have historical campaign and warranty data been
reviewed?
3 Have similar part DFMEAs been considered?
4 Does the SFMEA and/or DFMEA identify Special
Characteristics?
5 Have design characteristics that affect high risk
priority failure modes been identified?
6 Have appropriate corrective actions been
assigned to high risk priority numbers?
7 Have appropriate corrective actions been
assigned to high severity numbers?
8 Have risk priorities been revised when corrective
actions have been completed and verified?

Revision Date:

Prepared By:

Page 3 of 95
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
A. General
Does the design require:
1 l New materials?
/
2 l Special tooling? /

3 Has assembly build variation analysis been

considered?
4 Has Design of Experiments been considered?
5 Is there a plan for prototypes in place?
/
6 Has a DFMEA been completed?
/
7 Has a DFMA been completed?
8 Have service and maintenance issues been
considered?
9 Has the Design Verification Plan been
considered?
10 If yes, was it completed by a cross functional
team?
11 Are all specified tests, methods, equipment and
acceptance criteria clearly defined and
understood?
12 Have Special Characteristics been selected?
/

Page 4 of 95
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
13 Is bill of material complete?
/
14 Are Special Characteristics properly
documented?
B. Engineering Drawings
15 Have dimensions that affect fit, function and
durability been identified?
16 Are reference dimensions identified to minimize
inspection layout time?
17 Are sufficient control points and datum surfaces
identified to design functional gages?
18 Are tolerances compatible with accepted
manufacturing standards?
19 Are there any requirements specified that cannot
be evaluated using known inspection techniques?

C. Engineering Performance Specifications

20 Have all special characteristics been identified?

/
21 Is test loading sufficient to provide all conditions,
i.e., production validation and end use?
22 Have parts manufactured at minimum and
maximum specifications been tested?
23 Can additional samples be tested when a
reaction plan requires it, and still conduct
regularly scheduled in-process tests?

Page 5 of 95
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
24 Will all product testing be done in-house?
/
25 If not, is it done by an approved subcontractor?
/
26 Is the specified test sampling size and/or
frequency feasible?
27 If required, has customer approval been obtained
for test equipment?
D. Material Specification
28 Are special material characteristics identified?
/
29 Are specified materials, heat treat and surface
treatments compatible with the durability
requirements in the identified environment?
30 Are the intended material suppliers on the
customer approved list?
31 Will material suppliers be required to provide
certification with each shipment?
32 Have material characteristics requiring inspection
been identified? If so,

33 l Will characteristics be checked in-house?

/
34 l Is test equipment available?
/
35 l Will training be required to assure accurate
test results?

Page 6 of 95
 A-2 DESIGN INFORMATION CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
36 Will outside laboratories be used?
/
37 Are all laboratories used accredited (if required)?
/
Have the following material requirements been considered:
38 l Handling?
/
39 l Storage?
/
40 l Environmental?
/

Revision Date

Prepared By:

Page 7 of 95
 A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
Does the design require:
1 l New materials?
/
2 l Quick change?
/
3 l Volume fluctuations?
/
4 Mistake proofing?
l
/
Have lists been prepared identifying:
5 l New equipment?
/
6 l New tooling?
/
7 l New test equipment?
/
Has acceptance criteria been agreed upon for:
8 l New equipment?
/
9 l New tooling?
/
10 l New test equipment?
/
11 Will a preliminary capability study be conducted at
the tooling and/or equipment manufacturer?

12 Has test equipment feasibility and accuracy been

established?

Page 8 of 95
 A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
13 Is a preventive maintenance plan complete for
equipment and tooling?
14 Are setup instructions for new equipment and
tooling complete and understandable?
15 Will capable gages be available to run preliminary
process capability studies at the equipment
supplier's facility?
16 Will preliminary process capability studies be run
at the processing plant?
17 Have process characteristics that affect special
product characteristics been identified?
18 Were special product characteristics used in
determining acceptance criteria?
19 Does the manufacturing equipment have
sufficient capacity to handle forecasted
production and service volumes?
20 Is testing capacity sufficient to provide adequate
testing?

Revision Date

Prepared By:

Page 9 of 95
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Is the assistance of the customer's quality
assurance or product engineering activity needed
to develop or concur to the control plan?

2 Has the supplier identified who will be the quality

liaison with the customer?
3 Has the supplier identified who will be the quality
liaison with its suppliers?
4 Has the quality assurance system been reviewed
using the Chrysler, Ford, and General Motors
Quality System Assessment?

Are there sufficient personnel identified to cover:

5 l Control plan requirements?

/
6 l Layout inspection?
/
7 l Engineering performance testing?
/
8 l Problem resolution analysis?
/
Is there a documented training program that:
9 l Includes all employees?
/
10 l Lists whose been trained?
/
11 l Provides a training schedule?
/
Has training been completed for:
12 l Statistical process control?
/

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE CHRYSLER, FORD, AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 10 of 95
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
13 l Capability studies?
/
14 l Problem solving?
/
15 l Mistake proofing?
/
16 Other topics as identified?
l
/
17 Is each operation provided with process
instructions that are keyed to the control plan?
18 Are standard operator instructions available at
each operation?
19 Were operator/team leaders involved in
developing standard operator instructions?
Do inspection instructions include:
20 l Easily understood engineering performance
specifications?
21 l Test frequencies?
/
22 l Sample sizes?
/
23 l Reaction plans?
/
24 l Documentation?
/
Are visual aids:
25 l Easily understood?
/
26 l Available?
/
27 l Accessible? /

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE CHRYSLER, FORD, AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 11 of 95
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
28 l Approved?
/
29 Dated and current?
l
/
30 Is there a procedure to implement, maintain, and
establish reaction plans for statistical control
charts?
31 Is there an effective root cause analysis system in
place?
32 Have provisions been made to place the latest
drawings and specifications at the point of the
inspection?
33 Are forms/logs available for appropriate
personnel to record inspection results?
Have provisions been made to place the following at the monitored operation:
34 l Inspection gages?
/
35 l Gage instructions?
/
36 l Reference samples?
/
37 l Inspection logs? /

38 Have provisions been made to certify and

routinely calibrate gages and test equipment?
Have required measurement system capability studies been:
39 l Completed?
/
40 l Acceptable?
/

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE CHRYSLER, FORD, AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 12 of 95
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
41 Are layout inspection equipment and facilities
adequate to provide initial and ongoing layout of
all details and components?
Is there a procedure for controlling incoming product that identifies:
42 l Characteristics to be inspected?
/
43 l Frequency of
inspection? /
44 l Sample size? /

45 l Designated location for approved product?

/
46 l Disposition of nonconforming products?
/
47 Is there a procedure to identify, segregate, and
control nonconforming products to prevent
shipment?
48 Are rework/repair procedures available?
49 Is there a procedure to requalify
repaired/reworked material?
50 Is there an appropriate lot traceability procedure?

51 Are periodic audits of outgoing products planned

and implemented?
52 Are periodic surveys of the quality system
planned and implemented?
53 Has the customer approved the packaging
specification?

Revision Date

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE CHRYSLER, FORD, AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 13 of 95
 A-4 PRODUCT/PROCESS QUALITY CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date

Prepared By:

THIS CHECKLIST IS NOT INTENDED TO REPLACE THE CHRYSLER, FORD, AND GENERAL MOTORS QUALITY SYSTEM ASSESSMENT. Page 14 of 95
 A-5 FLOOR PLAN CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Does the floor plan identify all required process
and inspection points?
2 Have clearly marked areas for all material, tools,
and equipment at each operation been
considered?
3 Has sufficient space been allocated for all
equipment?
Are process and inspection areas:
4 l Of adequate
size? /
5 l Properly lighted?
/
6 Do inspection areas contain necessary
equipment and files?
Are there adequate:
7 l Staging
areas? /
8 l Impound
areas? /
9 Are inspection points logically located to prevent
shipment of nonconforming products?
10 Have controls been established to eliminate the
potential for an operation, including outside
processing, to contaminate or mix similar
products?
11 Is material protected from overhead or air
handling systems contamination?
12 Have final audit facilities been provided?

Page 15 of 95
 A-5 FLOOR PLAN CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
13 Are controls adequate to prevent movement of
nonconforming incoming material to storage or
point of use?

Revision Date

Prepared By:

Page 16 of 95
 A-6 PROCESS FLOW CHART CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Does the flow chart illustrate the sequence of
production and inspection stations?
2 Were all appropriate FMEA's (SFMEA, DFMEA)
available and used as aids to develop the
process flow chart?
3 Is the flow chart keyed to product and process
checks in the control plan?
4 Does the flow chart describe how the product will
move, i.e., roller conveyor, slide containers, etc.?

5 Has the pull system/optimization been considered

for this process?
6 Have provisions been made to identify and
inspect reworked product before being used?
7 Have potential quality problems due to handling
and outside processing been identified and
corrected?

Revision Date

Prepared By:

Page 17 of 95
 A-7 PROCESS FMEA CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Was the Process FMEA prepared using the
Chrysler, Ford, and General Motors guidelines?

2 Have all operations affecting fit, function,

durability, governmental regulations and safety
been identified and listed sequentially?
3 Were similar part FMEA's considered?
4 Have historical campaign and warranty data been
reviewed?
5 Have appropriate corrective actions been planned
or taken for high risk priority items?
6 Have appropriate corrective actions been planned
or taken for high severity numbers?
7 Were risk priorities numbers revised when
corrective action was completed?
8 Were high severity numbers revised when a
design change was completed?
9 Do the effects consider the customer in terms of
the subsequent operation, assembly, and
product?
10 Was warranty information used as an aid in
developing the Process FMEA?
11 Were customer plant problems used as an aid in
developing the Process FMEA?
12 Have the causes been described in terms of
something that can be fixed or controlled?
13 Where detection is the major factor, have
provisions been made to control the cause prior
to the next operation?

Revision Date

Page 18 of 95
 A-7 PROCESS FMEA CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
Prepared By:

Page 19 of 95
 A-8 CONTROL PLAN CHECKLIST
Customer or Internal Part No. NUMBER

Person Due
Question Yes No Comment / Action Required
Responsible Date
1 Was the control plan methodology referenced in
Section 6 used in preparing the control plan?

2 Have all known customer complaints been

identified to facilitate the selection of special
product/process characteristics?
3 Are all special product/process characteristics
included in the control plan?
4 Were SFMEA, DFMEA, and PFMEA used to
prepare the control plan?
5 Are material specifications requiring inspection
identified?
6 Does the control pan address incoming
(material/components) through
processing/assembly including packaging?
7 Are engineering performance testing
requirements identified?
8 Are gages and test equipment available as
required by the control plan?
9 If required, has the customer approved the
control plan?
10 Are gage methods compatible between supplier
and customer?

Revision Date

Prepared By:

Page 20 of 95
 TEAM FEASIBILITY COMMITMENT
Customer: GM Date:

Part Number: NUMBER Part Name: NAME

Feasibility Considerations
Our product quality planning team has considered the following questions, not intended to be all-inclusive in
performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc. to enable
feasibility evaluation?
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk's that meet requirements?
Is there adequate capacity to produce product?
Does the design allow the use of efficient material handling techniques?
Can the product be manufactured without incurring any unusual:
- Costs for capital equipment?
- Costs for tooling?
- Alternative manufacturing methods?
Is statistical process control required on the product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
- Are the processes in control and stable?
- Are Cpk's greater than 1.33?

Conclusion

Feasible Product can be produced as specified with no revisions.

Feasible Changes recommended (see attached).
Not Feasible Design revision required to produce product within the specified requirements.

Sign-Off

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

 PRODUCT QUALITY PLANNING SUMMARY AND SIGN-OFF
DATE:

PRODUCT NAME: NAME PART NUMBER: NUMBER

CUSTOMER: GM MANUFACTURING PLANT: CITY

1. PRELIMINARY PROCESS CAPABILITY STUDY QUANTITY

REQUIRED ACCEPTABLE PENDING*
Ppk - SPECIAL CHARACTERISTICS

2. CONTROL PLAN APPROVAL (If Required) APPROVED: YES / NO* DATE APPROVED

3. INITIAL PRODUCTION SAMPLES

CHARACTERISTIC CATEGORY QUANTITY
CHARACTERISTICS
SAMPLES PER SAMPLE ACCEPTABLE PENDING*
DIMENSIONAL
VISUAL
LABORATORY
PERFORMANCE

4. GAGE AND TEST EQUIPMENT

MEASUREMENT SYSTEM ANALYSIS QUANTITY
REQUIRED ACCEPTABLE PENDING*
SPECIAL CHARACTERISTIC

5. PROCESS MONITORING
QUANTITY
PROCESS MONITORING INSTRUCTIONS REQUIRED ACCEPTABLE PENDING*
PROCESS SHEETS
VISUAL AIDS

6. PACKAGING/SHIPPING QUANTITY
REQUIRED ACCEPTABLE PENDING*
PACKAGING APPROVAL
SHIPPING TRIALS

7. SIGN-OFF

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

TEAM MEMBER/TITLE/DATE TEAM MEMBER/TITLE/DATE

* REQUIRES PREPARATION OF AN ACTION PLAN TO TRACK PROGRESS.

SUPPLIER ORGANIZATION PROGRAM APPLICATION
MFG. LOCATION ADDRESS SUPPLIER CODE CODE
PART NUMBER(S) NUMBER PART NAME(S) NAME DaimlerChrysler
CHANGE LEVEL(S) ECL PRE-PSO MEETING DATE PSO
PSO ON-SITE VISIT DATE / NUMBER 5th Edition

SUPPLIER READINESS EVALUATION

QUANTITY DETERMINED BY SUPPLIER AND

DAIMLERCHRYSLER PSO TEAM:

SRE LINE RATE:

SHIFT:

PERFORMANCE RESULTS
FTC Percent
ITEM Process Feature / Part Meas. Part / Proc. Quantity Quantity %
Process / Part1 USL UCL LCL LSL Pp Ppk (without ACC / REJ
# Characteristic Freq. Avg. Attempted Accepted GR&R
repairs)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Notes: 1
Measurement Taken During In-Process / or Final Inspection
 DaimlerChrysler PSO Status Summary

SSP PSO Status: S1 Date: V1 Date: Assembly: Press Room: Total: Percent Signed:
Last
Updated: Status by PSO Item Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Parts
Part Number Description Asy or Stp'g Part Num. Process Incoming M. Parts Tooling, Error & Preventive
Design Tst Sample Process Quality Special Proc Process Evidence of Line Speed Outgoing Packaging & Gage & Test
Des & Chg Flow Diag. & Control Plan Qual / Cert Handling Op Instr Equip. & Mistake LPA Plan Mainten-
FMEA Size & Freq. FMEA Planning / Prod Ident. Monitoring Prod. Spec. Demo Qual. Plan Shipping Eval.
Lvl Mfg Flr Run Run Plan Gages Ident. Proofing ance
Spec.

Due Date >>

% Complete>> 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

Key Contact

Legend: 0% 25% 50% 75% 100% N A Not Applicable

I Incomplete R Completed / Rejection-Action Required C Condition Approval - Open Issues A Completed Approved
 DAIMLERCHRYSLER PROCESS SIGN-OFF SUMMARY REPORT
ALL PROCESS SIGN-OFF ELEMENTS APPROVED: PSO EXTENDED RUN:
SUPPLIER ORGANIZATION YES NO YES NO OPTIONS

MFG. LOCATION CITY SUPPLIER CODE CODE

PART NUMBER(S) NUMBER PART NAME(S) NAME

CHANGE LEVEL(S) ECL PRE-PSO MEETING DATE

PROGRAM APPLICATION PSO ON-SITE VISIT DATE / NUMBER

* Documents with asterisk should be reviewed during AQP meeting and again during the Pre-PSO documentation Review.
PSO PROCESS ELEMENTS
DOCUMENTATION PROCESS
Accept Reject Accept Reject
1 PART NUMBER, DESCRIPTION AND
CHANGE LEVEL
*Cross reference sheet Yes No Acceptable Supplier change Yes No
(IF APPLICABLE) notice procedure
Evidence of customer change
1.4 Engineering Standards Identified notice procedure
Yes No Process for obtaining the latest Yes No
*CATIA comments page standard revision
with list of applicable standards
(e.g. DCC, ENVIRONMENTAL, etc.)
Accept Reject Accept Reject
2 DESIGN FMEA
*Design FMEA complete Yes No DFMEA updated to include Yes No
& acceptable applicable DV failures
Accept Reject
3 TEST SAMPLE SIZES AND FREQUENCIES
Yes No
*Signed DV and PV plans
*Signed DVP&R (DV complete)
*Signed waivers (IF APPLICABLE)
Accept Reject Accept Reject
4 PROCESS FMEA Process correlates with
*Process FMEA complete Yes No occurrence and detection Yes No
& acceptable numbers on PFMEA
Accept Reject Accept Reject
5 PROCESS FLOW DIAGRAM & MFG FLOOR PLAN
Yes No SPC operations identified Yes No
*Flow diagram on flow diagram
*Manufacturing floor plan Unique Equipment numbers
*Work station layout identified on mfg floor plan,
Accept Reject flow diagram, or workstation layout Accept Reject
6 CONTROL PLAN
*Process characteristics Yes No Proper adherence to Yes No
identified on the Control Plan Control Plan
*Verification of mistake Rework / Repair stations
proofing on the Control Plan have acceptable controls
Accept Reject (IF APPLICABLE)
7 QUALITY PLANNING
Yes No
*Completed PAP/APQP
PSO Summary Matrix
7.2 Supply Base Management Yes No
*Easy Map, Etc.
Risked sub-components
Level 3 PPAP data
7.3 Problem Solving Methods Yes No
*Example of DOE's, etc.
SID'S for DCC systems
*Example of problem
solving techniques
Accept Reject Accept Reject
8 INCOMING MATERIAL QUALIF / CERT PLAN
Yes No Yes No
Certificates of analysis Evidence of sub-tier monitoring
Copy of sub-tier PSW's Proof of lot control
*Plan for lot control Proof or traceability
*Plan for traceability

COPYRIGHT 2005 DaimlerChrysler Corporation Page 25 of 5

 PSO PROCESS ELEMENTS
SUPPLIER NAME: ORGANIZATION
PART NUMBER NUMBER DOCUMENTATION PROCESS
Accept Reject Accept Reject
9 PARTS HANDLING PLAN
Yes No Evidence of acceptable Yes No
*Router / Traveler Cards part handling
*Parts handling Plan Yes No
*Container Maintenance Acceptable method of
plan inventory control
Accept Reject Accept Reject
10 OPERATING INSTRUCTIONS
Yes No Visual displays clearly present Yes No
*Work Instructions (WI's) at each station
*Inspection instructions Operators follow WI's
*Rework / repair Evidence of proper operator
instructions (IF APPLICABLE) Accept Reject training Accept Reject
11 TOOLING, EQUIPMENT AND GAGES
IDENTIFIED Yes No STR in agreement with Supplier's Yes No
*Tooling and equipment list manufacturing facility
*Supplier tool record DCC ownership tags present
12 SPECIAL PRODUCT AND PROCESS Accept Reject Accept Reject
CHARACTERISTICS IDENTIFIED
Yes No SPC performed for identified Yes No
*FPSC plan acceptable and special characteristics
contains special process /
product characteristics Accept Reject Accept Reject
13 PROCESS MONITORING
Yes No Acceptable 1st piece approval Yes No
*Control charts process
*1st piece approval procedure 1st approval records
Control & Performance charts
14 ERROR AND MISTAKE PROOFING Accept Reject maintained appropriately Accept Reject

Yes No Boundary samples created Yes No

*Error & mistake proofing plan & utilized
*List of error & mistake proofing Mistake proofing contingency
Accept Reject plan with audible / visual alarm Accept Reject
15 LAYERED PROCESS AUDIT PLAN
Yes No Yes No
*Acceptable LPA plan Acceptable LPA performed
*Frequency and structure chart
16 EVIDENCE OF Accept Reject Accept Reject
PRODUCT SPECIFICATIONS
Yes No Completed and approved Yes No
*SRE completed and Measurement System
acceptable Accept Reject Verification Report Accept Reject
17 LINE SPEED DEMONSTRATION Yes No
Contingency plan for
bottlenecks (IF APPLICABLE)
Line Speed Observed FTC:
Accept Reject Accept Reject
18 OUTGOING QUALIFICATION PLAN
Yes No Evidence of non-conformance Yes No
*Outgoing inspection plan containment
*Part Inspection Standard Evidence of outgoing audits
Accept Reject (USING PART INSPECTION STANDARD) Accept Reject
19 PARTS PACKAGING & SHIPPING SPECS
Yes No
*Packaging & shipping plan *Acceptable container Yes No
management plan
20 GAGE AND TEST EQUIPMENT EVALUATION Accept Reject Accept Reject

Yes No Appropriate gages used in Yes No

*Gage R&R studies the process
*Calibration plan & schedule Calibration performed
according to schedule

COPYRIGHT 2005 DaimlerChrysler Corporation Page 26 of 5

 PSO PROCESS ELEMENTS
SUPPLIER NAME: ORGANIZATION
PART NUMBER NUMBER DOCUMENTATION PROCESS
Accept Reject Accept Reject
21 PREVENTIVE MAINTENANCE PLANS
Yes No PM performed according to Yes No
*PM plan schedule
*PM schedule Robust PM process
*PM procedures and WI's All tooling / equipment listed on
Accept Reject PM schedule Accept Reject
22 INITIAL PROCESS STUDY
Yes No Yes No
Deviations (IF APPLICABLE) Acceptable FTC
Acceptable process capability
Sample size Ppk requirement

PSO PROCESS ELEMENTS REQUIRED FOR FULL APPROVAL

DOCUMENTATION PROCESS
Accept Reject Accept Reject
23 PACKAGING SHIPPING TEST APPROVAL
Yes No Yes No
Signed shipping / simulation Shipping simulation testing
test approval (MHE mtg minutes) Accept Reject complete Accept Reject
24 PRODUCTION VALIDATION
TESTING COMPLETE Yes No Yes No
Signed DVP&R (PV complete) BSR/NVH testing complete
Signed Waivers (IF APPLICABLE) PV testing complete
Repair / rework process
Accept Reject validation complete (IF APPLICABLE) Accept Reject
25 CONTINUOUS CONFORMANCE (CC)
Continuous conformance team Yes No CC team is sufficient to Yes No
identified and trained support post-PSO activities
Warranty process flow diagram Acceptable process for
Forever requirements warranty analysis Yes No
submission procedure Family PV testing agreed to
by the PSO team

Vehicle families included in family OV:

CORRECTIVE ACTION REQUIRED YES NO DATE

ON-SITE REVISIT REQUIRED YES NO DATE

Process Sign-Off Team Manufacturing Facility

ENGINEERING PRINT NAME, SIGN AND DATE QUALITY ASSURANCE MANAGER PRINT NAME, SIGN AND DATE

SUPPLIER QUALITY PRINT NAME, SIGN AND DATE MANUFACTURING MANAGER PRINT NAME, SIGN AND DATE

PRINT NAME, SIGN AND DATE PLANT MANAGER PRINT NAME, SIGN AND DATE
Additional Signatures Needed for Internal PSO's

PRODUCT ENGINEERING PRINT NAME, SIGN AND DATE MANUFACTURING LINE SPVSR. PRINT NAME, SIGN AND DATE

RESIDENT ENGINEERING MGR. PRINT NAME, SIGN AND DATE MQAS COORDINATOR PRINT NAME, SIGN AND DATE

AME TOOL ENGINEER PRINT NAME, SIGN AND DATE

AME SENIOR MANAGER PRINT NAME, SIGN AND DATE

COPYRIGHT 2005 DaimlerChrysler Corporation Page 27 of 5

1st or 2nd Party PSO Lead PRINT NAME, SIGN AND DATE

SUPPLIER ORGANIZATION PROGRAM APPLICATION

MFG. LOCATION CITY SUPPLIER CODE CODE

DaimlerChrysler
PART NUMBER(S) NUMBER PART NAME(S) NAME PSO
CHANGE LEVEL(S) ECL PRE-PSO MEETING DATE 5th Edition

PSO ON-SITE VISIT DATE / NUMBER

PROCESS SIGN-OFF
COMMENTS SHEET
ELEMENT NO. ISSUE / ACTION RESPONSIBILITY TARGET

COPYRIGHT 2005 DaimlerChrysler Corporation Page 28 of 5

SUPPLIER ORGANIZATION PROGRAM APPLICATION

MFG. LOCATION CITY SUPPLIER CODE CODE

DaimlerChrysler
PART NUMBER(S) NUMBER PART NAME(S) NAME
PSO
CHANGE LEVEL(S) ECL PRE-PSO MEETING DATE 5th Edition

PSO ON-SITE VISIT DATE / NUMBER

MEASUREMENT SYSTEM VERIFICATION REPORT

As part of the PSO, the actual measurement process must be witnessed by the PSO Team.
- A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,
the number of characteristics selected depends upon the complexity.
- A minimum of 30 randomly selected samples shall be checked during the PSO on-site visit.
- Variable data is preferred but attribute data is acceptable.
- Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual) for Ppk requirements.
- For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.
- All deviations shall be listed in the COMMENTS section of this document.

SUMMARY EXAMPLE
QUANTITY QUANTITY FTC PERCENTAGE PROCESS
CHARACTERISTIC SPECIFICATION METHOD OF MEASUREMENT Pp / Ppk
ATTEMPTED ACCEPTED (without repair) ACC / REJ
Length 3.6 - 7.5mm Caliper 30 30 100% 1.7/1.6 ACC
Hole Size 2.0 +/- 0.2mm CMM 30 28 93% 2.3/2.2 REJ

Number of parts witnessed: Witnessed By:

DATA
QUANTITY QUANTITY FTC PERCENTAGE PROCESS
CHARACTERISTIC SPECIFICATION METHOD OF MEASUREMENT Pp / Ppk
ATTEMPTED ACCEPTED (without repair) ACC / REJ

COMMENTS:

Page 5 of 5
 PRODUCTION DEMONSTRATION RESULTS
SUPPLIER ORGANIZATION PROGRAM APPLICATION DaimlerChrysler
MFG. LOCATION ADDRESS SUPPLIER CODE CODE PSO
PART NUMBER(S) NUMBER PART NAME(S) NAME 5th Edition
CHANGE LEVEL(S) ECL PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE / NUMBER

Line Speed Demonstration

Line Shared (Y/N):
Quoted Net DC Number of shifts (SH):
Line Speed Part Quantity Duration of Line Speed % of DC
Tooling Operating Part Quantity Ran FTC
Required Accepted Run Demonstrated Capacity Hours / Shift (HR):
Capacity Time
Days / Week (DY):
Other Customer Capacity
Excess Capacity Available
COMMENTS

Note: Pieces per hour shall be greater than or equal to the Line Speed Required.
FTC shall be 90% or greater or a signed waiver from the appropriate Supplier Quality Manager is required.

Summary Example
FTC Percent
ITEM Process Feature / Part Meas. Part / Proc. Quantity Quantity %
Process / Part1 USL UCL LCL LSL Pp Ppk (without ACC / REJ
# Characteristic Freq. Avg. Attempted Accepted GR&R
repairs)
1 P025 Gap - Machine 66 Part 2/Shift 0.097 0.009 0.0874 0.0851 0.077 2.5 2.28 30 30 100% 9.37 ACC
2 P025 Gap - Machine 67 Part 2/Shift 0.097 0.009 0.0874 0.0851 0.077 2.54 2.41 30 30 100% 12.7 ACC

Initial Process Study

FTC Percent
ITEM Process Feature / Part Meas. Part / Proc. Quantity Quantity %
Process / Part1 USL UCL LCL LSL Pp Ppk (without ACC / REJ
# Characteristic Freq. Avg. Attempted Accepted GR&R
repairs)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Notes: 1
Measurement Taken During In-Process / or Final Inspection

Page 30 of 95
 PART HISTORY
Part Number Part Name
NUMBER NAME

Date Remarks

Page 31 of 95
 PROCESS / INSPECTION FLOWCHART

Product Program Issue Date ECL ECL

Supplier Name ORGANIZATION Part Name NAME
Supplier Location CITY STATE Part Number NUMBER

Legend:
Operation Transportation Inspection Delay Storage

Operation or Event Description of Evaluation

STEP

Operation or Event and Analysis Methods

Page 32 of 95
 PROCESS FLOW DIAGRAM
PART NUMBER: NUMBER DATE:
PART DESCRIPTION: ECL: ECL
NAME PREPARED BY:
FABRICATION

INSPECT
STORE
MOVE

PRODUCT AND

ITEM #

ITEM #
OPERATION PROCESS CONTROL
STEP DESCRIPTION CHARACTERISTICS METHODS

Page 33 of 95
 PROCESS FLOW JOB #
Part # ECL Process Responsibility Prepared By
NUMBER
Part Name Product Line Core Team Date (revised)
NAME
Component to Assembly Name Key Date Date (original)

Process Flow Diagram Operation Potential Quality Problems Product Characteristics Process Characteristics

operation w/auto inspection

w/mult product streams

transportation storage

inspection

decision Delay

operator partial

rework R
 CHARACTERISTIC MATRIX
Part Number Engineering Change Level Part Name
NUMBER ECL NAME

C = Characteristic at an operation used for clamping

L = Characteristic at an operation used for locating
X = Characteristic created or changed by this operation should
match the process flow diagram form

DIMENSION OPERATION NUMBER

NUMBER DESCRIPTION TOLERANCE

Page 35 of 95
DESIGN MATRIX -
Product Code / Description: Project #:
POTENTIAL CAUSES FUNCTION - DESIRED ATTRIBUTES (POTENTIAL FAILURE MODES)

ROBUST THRESHOLD RANGE

Prelim. Special Characteristics

PROCESS ABILITY

ENVIRONMENTAL
FAILURE

UNITS

PERFORMANCE
CATEGORY /

APPEARANCE
CHARACTERISTICS

NEGATIVE IMPACT ON CUSTOMER EXPECTATIONS: HIGH = 3; MED = 2; LOW = 1; NONE = 0; UNKNOWN = ?

 System POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Subsystem (DESIGN FMEA) FMEA Number: FILE.XLS
Component Design Responsibility: ORGANIZATION Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Core Team: Date (Rev.)

C O Current D
Potential c Design e R. Responsibility Action Results
Item /
Potential Potential S l
Causes(s)/ Recommended & Target
Failure Effect(s) e a c Controls t P. S O D R.
Function Mechanism(s) u -Prevention e N. Action(s) Completion Actions e c e P.
Mode of Failure v s of Failure Date Taken
s r -Detection c v c t N.

Page 37 of 95
 System POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Subsystem (DESIGN FMEA) FMEA Number: FILE.XLS
Component Design Responsibility ORGANIZATION Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Core Team: Date (Rev.)

C O D
Potential c Current Current e R. Responsibility Action Results
Item /
Potential Potential S l
Causes(s)/ Process Process Recommended & Target
Failure Effect(s) e a c t P. S O D R.
Function Mechanism(s) u Controls Controls e N. Action(s) Completion Actions e c e P.
Mode of Failure v s of Failure Prevention Detection Date Taken
s r c v c t N.

Page 38 of 95
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # NUMBER Rev. ECL (PROCESS FMEA) FMEA Number: FILE.XLS
Item: NAME Process Responsibility: ORGANIZATION Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Core Team: Date (Rev.)

C O Current D
Process Potential c Process e R. Responsibility Action Results
Function/
Potential Potential S l
Causes(s)/ Recommended & Target
Failure Effect(s) e a c Controls t P. S O D R.
Require- Mechanism(s) u -Prevention e N. Action(s) Completion Actions e c e P.
ments
Mode of Failure v s of Failure Date Taken
s r -Detection c v c t N.

Page 39 of 95
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # NUMBER Rev. ECL (PROCESS FMEA) FMEA Number: FILE.XLS
Item: NAME Process Responsibility ORGANIZATION Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Core Team: Date (Rev.)
C O D
Process S l Potential c Current Current e R. Responsibility Action Results
Potential Potential
Function/ e a Causes(s)/ c Process Process t P. Recommended & Target S O D R.
Failure Effect(s)
Require- v s Mechanism(s) u Controls Controls e N. Action(s) Completion Actions e c e P.
Mode of Failure
ments of Failure Prevention Detection Date Taken
s r c v c t N.

Page 40 of 95
 System POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Subsystem (MACHINERY FMEA) FMEA Number: FILE.XLS
Component Supplier Name ORGANIZATION Prepared by:
Program(s) / Plant(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C O Current D
S l Potential c Machinery e R. Responsibility Action Results
Machinery Potential Potential
e a Causes(s)/ c Controls t P. Recommended & Target S O D R.
Function / Failure Effect(s)
v s Mechanism(s) u -Prevention e N. Action(s) Completion Actions e c e P.
Requirements Mode of Failure
of Failure Date Taken
s r -Detection c v c t N.

Page 41 of 95
 System POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Subsystem (MACHINERY FMEA) FMEA Number: FILE.XLS
Component Supplier Name ORGANIZATION Prepared by:
Program(s) / Plant(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C O D
S l Potential c Current Current e R. Responsibility Action Results
Machinery Potential Potential
e a Causes(s)/ c Process Process t P. Recommended & Target S O D R.
Function / Failure Effect(s)
v s Mechanism(s) u Controls Controls e N. Action(s) Completion Actions e c e P.
Requirements Mode of Failure
of Failure Prevention Detection Date Taken
s r c v c t N.

Page 42 of 95
 CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
FILE.XLS 555-555-5555 1/1/1996 1/1/1996
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
NUMBER ECL
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
ORGANIZATION CODE
PART/ MACHINE, CHARACTERISTICS SPECIA METHODS
PROCESS NAME/
PROCES DEVICE L PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
OPERATION
S JIG, TOOLS CHAR. SPECIFICATION/ MEASUREMENT CONTROL PLAN
DESCRIPTION NO. PRODUCT PROCESS
NUMBER FOR MFG. CLASS SIZE FREQ. METHOD
TOLERANCE TECHNIQUE

Page 43 of 95
 CONTROL PLAN SPECIAL CHARACTERISTICS
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
FILE.XLS 555-555-5555 1/1/1996 1/1/1996
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
NUMBER ECL
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
ORGANIZATION CODE
No. Description/Rationale Specification/Tolerance Class Illustration/Pictorial

Page 44 of 95
 DATA POINT COORDINATES
Control Plan No. Part Number Engineering Change Level Date(Orig):
FILE.XLS NUMBER ECL 1/1/1996
Part Name Customer Supplier Date(Rev):
NAME GM ORGANIZATION 1/1/1996

Char. Point Char. Point Char. Point

X Y Z X Y Z X Y Z
No. Ident. No. Ident. No. Ident.

Page 45 of 95
 Dynamic Control Plan - Master Copy
Company/Plant Department Operation Station Part Name Control Plan Revision Date
ORGANIZATION NAME
Process Machine Part Number Process sheet revision date B/P revision date
NUMBER ECL DATE
Characteristic C
Char Description Spec T I Failure Effects S Causes O Current D R Recom. Area Actions S O D R Ctrl. l Control T Gage desc, GR&R Cp/Cpk Reaction
# y m Mode of E of C Controls E P Actions Respon. Taken E C E P Fact. a Method o master, & (target) Plans
(Product & p p failure V Failure C T N & Date V C T N s o detail Date & Date
Process) e s l

Page 46 of 95
 Dynamic Control Plan - Operator Copy
Department Operation Part Name Control Plan Revision Date
NAME
Process Machine Part Number Process Sheet Revision Date B/P Revision Date
NUMBER ECL DATE
C
Char Characteristic Spec l Control Current Gage desc, Reaction
# Description a Method Controls master, Plans
s detail
s

Page 47 of 95
 Production Part Approval Page 48 of 95 Pages

Dimensional Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE:CODE PART NAME: NAME
INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL: ECL
ENGINEERING CHANGE DOCUMENTS:

DIMENSION / SPECIFICATION / TEST QTY. ORGANIZATION MEASUREMENT NOT

ITEM OK
SPECIFICATION LIMITS DATE TESTED RESULTS (DATA) OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

March CFG-1003
2006
 Production Part Approval Page 49 of 95 Pages

Dimensional Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE:CODE PART NAME: NAME
INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL: ECL
ENGINEERING CHANGE DOCUMENTS:

DIMENSION / SPECIFICATION / TEST QTY. ORGANIZATION MEASUREMENT NOT

ITEM OK
SPECIFICATION LIMITS DATE TESTED RESULTS (DATA) OK

March CFG-1003
2006
 Production Part Approval Page of Pages

Material Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE: CODE PART NAME: NAME
MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL: ECL
*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:
SPECIFICATION / TEST QTY. NOT
MATERIAL SPEC. NO. / REV / DATE SUPPLIER TEST RESULTS (DATA) OK
LIMITS DATE TESTED OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

March CFG-1004
2006
 Production Part Approval Page of Pages

Material Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE: CODE PART NAME: NAME
MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL: ECL
*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:
SPECIFICATION / TEST QTY. NOT
MATERIAL SPEC. NO. / REV / DATE SUPPLIER TEST RESULTS (DATA) OK
LIMITS DATE TESTED OK

March CFG-1004
2006
 Production Part Approval Page 52 of 95 Pages

Performance Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE: CODE PART NAME: NAME
NAME of LABORATORY: DESIGN RECORD CHANGE LEVEL: ECL
*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

SPECIFICATION / TEST QTY. SUPPLIER TEST RESULTS (DATA)/ NOT

TEST SPECIFICATION / REV / DATE OK
LIMITS DATE TESTED TEST CONDITIONS OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

March CFG-1005
2006
 Production Part Approval Page 53 of 95 Pages

Performance Test Results

ORGANIZATION: ORGANIZATION PART NUMBER: NUMBER
SUPPLIER / VENDOR CODE: CODE PART NAME: NAME
NAME of LABORATORY: DESIGN RECORD CHANGE LEVEL: ECL
*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

SPECIFICATION / TEST QTY. SUPPLIER TEST RESULTS (DATA)/ NOT

TEST SPECIFICATION / REV / DATE OK
LIMITS DATE TESTED TEST CONDITIONS OK

March CFG-1005
2006
 APPEARANCE APPROVAL REPORT
PART DRAWING APPLICATION
NUMBER NUMBER NUMBER (VEHICLES) APPLICATION
PART BUYER E/C LEVEL DATE
NAME NAME CODE ECL
ORGANIZATION MANUFACTURING ADDRESS SUPPLIER / VENDOR
NAME ORGANIZATION LOCATION CITY STATE ZIP CODE CODE
REASON FOR PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION OTHER
SUBMISSION PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
ORGANIZATION SOURCING AND TEXTURE INFORMATION PRE-TEXTURE REPRESENTATIVE
EVALUATION SIGNATURE AND DATE
CORRECT AND
PROCEED

CORRECT AND
PROCEED

APPROVED TO
ETCH/TOOL/EDM

COLOR EVALUATION
METALLIC COLOR
COLOR TRISTIMULUS DATA MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS BRILLIANCE SHIPPING PART
SUFFIX DL* Da* Db* DE* CMC NUMBER DATE TYPE SOURCE RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW SUFFIX DISPOSITION

COMMENTS

ORGANIZATION PHONE NO. DATE AUTHORIZED CUSTOMER DATE

SIGNATURE REPRESENTATIVE SIGNATURE

March CFG-1002
2006
 ATTRIBUTE GAGE BIAS REPORT
ANALYTICAL METHOD - LOW LIMIT
Part Number Gage Name Appraiser
NUMBER
Part Name Gage Number Date Performed
NAME
Characteristic Gage Type Upper Limit Lower Limit

ATTRIBUTE DATA
# XT a P'a After entering data, follow the directions on the tab marked
1 0.000 'Graph' to create the Gage Performance Curve
2 0.000
3 0.000
4 0.000
5 0.000
6 0.000
7 0.000
8 0.000
9 0.000

FROM THE GRAPH

ENTER THE FOLLOWING:
XT (P=.5) =
XT (P=.995) =
XT (P=.005) =

Measurement Unit Analysis

Bias Repeatability
B = R =
= =

t Statistic
t = 31.3 IBI / R t0.025,19 = 2.093
=
=

Result

Page 55 of 95
 ATTRIBUTE GAGE BIAS REPORT
ANALYTICAL METHOD - HIGH LIMIT
Part Number Gage Name Appraiser
NUMBER
Part Name Gage Number Date Performed
NAME
Characteristic Gage Type Upper Limit Lower Limit

ATTRIBUTE DATA
# XT a P'a After entering data, follow the directions on the tab marked
1 0.025 'Graph' to create the Gage Performance Curve
2 0.000
3 0.000
4 0.000
5 0.000
6 0.000
7 0.000
8 0.000
9 0.000

FROM THE GRAPH

ENTER THE FOLLOWING:
XT (P=.5) =
XT (P=.995) =
XT (P=.005) =

Measurement Unit Analysis

Bias Repeatability
B = R =
= =

t Statistic
t = 31.3 IBI / R t0.025,19 = 2.093
=
=

Result

Page 56 of 95
 ATTRIBUTE GAGE BIAS REPORT
ANALYTICAL METHOD - GAGE PERFORMANCE CURVE
Part Number Gage Name Appraiser
NUMBER
Part Name Gage Number Date Performed
NAME
Characteristic Gage Type Upper Limit Lower Limit

LOW LIMIT RESULTS* HIGH LIMIT RESULTS*

Bias Bias
GRR GRR
sGRR sGRR
*Curve can be generated from low or high limit results if symmetry is assumed.

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0
0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000

REMARKS

Signature

Title Date

Page 57 of 95
Directions for Gage Performance Curve for Attribute Analytical Method Form

1) Click Tools - Data Analysis - Regression

(If Data Analysis is not available load Analysis Tool Pak from the Add-Ins menu)
2) In the box for Input Y Range select the cells ATT BIAS(Analytic)!D14:D22
3) In the box for Input X Range select the cells ATT BIAS(Analytic)!B14:B22
4) In the box for Output range select the cells below A23:M60
5) Check Line Fit Plots
6) Press OK
7) Copy the Line Fit plot graph to the space on the Analytic sheet
8) Change the graph title to GPC - Low Side Normal Prob Paper
9) Change the x axis to Xt
10) Change the y axis to Probability
11) Repeat for high side data

Gage Performance Curve

15

Probability
10
5
0
0 2 4 6 8 10 12
Xt
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

DATA TABLE
Reference
PART A-1 A-2 A-3 B-1 B-2 B-3 C-1 C-2 C-3 Reference Value Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Page 59 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

DATA TABLE CONTINUED

Reference
PART A-1 A-2 A-3 B-1 B-2 B-3 C-1 C-2 C-3 Reference Value Code
41
42
43
44
45
46
47
48
49
50

Risk Analysis
A * B Crosstabulation

B
Total
0 1
0 Count 0 0 0
Expected Count
A
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

B * C Crosstabulation

C
Total
0 1
0 Count 0 0 0
Expected Count
B
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

Page 60 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

A * C Crosstabulation

C
Total
0 1
0 Count 0 0 0
Expected Count
A
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

Kappa A B C
A -
B -
C -

DETERMINATION
AxB 0.75 or higher indicates good agreement
AxC Between 0.40 and 0.75 indicates some agreement
BxC Less then 0.40 indeicates poor agreement

A * REF Crosstabulation

REF
Total
0 1
0 Count 0 0 0
Expected Count
A
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

Page 61 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

B * REF Crosstabulation

REF
Total
0 1
0 Count 0 0 0
Expected Count
B
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

C * REF Crosstabulation

REF
Total
0 1
0 Count 0 0 0
Expected Count
C
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count

A B C
Kappa

DETERMINATION
A x REF 0.75 or higher indicates good agreement
B x REF Between 0.40 and 0.75 indicates some agreement
C x REF Less then 0.40 indeicates poor agreement

Page 62 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

% Appraiser1 % Score vs. Attribute2

Source Appraiser A Appraiser B
Appraiser C Appraiser A Appraiser B Appraiser C
Total Inspected
# Matched 0 0 0 0 0 0
False Positive (appraiser biased towards rejection) 0 0 0
False Negative (appraiser biased towards acceptance) 0 0 0
Mixed
95% UCI5
Calculated Score
95% LCI5

System % Effective Score3 System % Effective Score vs. Reference4

Total Inspected
# in Agreement 0 0
95% UCI5
Calculated Score
95% LCI5

Notes:
(1) Appraiser agress with themself on all trials
(2) Appraiser agrees on all trials with the known standard
(3) All appraisers agreed within and between themselves
(4) All appraisers agreed within and between themselves and with the reference
(5) UCI and LCI are the upper and lower confidence internval bounds, respectively (Wilson score method)

H0: The effectiveness of both appraisers is the same (Null hypothesis)

HA: The effectiveness of both appraisers is not the same (Alternative Hypothesis)

Acceptance criteria: The calculated score of the appraiser falls between the confidence interval of the other.

EFFECTIVENESS EVALUATION
Appraiser A vs. Appraiser B Reject Null Hypothesis Accept Alternative
Appraiser A vs. Appraiser C Reject Null Hypothesis Accept Alternative
Appraiser B vs. Appraiser C Reject Null Hypothesis Accept Alternative

Page 63 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
ATTRIBUTE HYPOTHESIS TEST METHOD
Part Number Gage Name Date Performed Appraiser A
NUMBER
Part Name Gage Number Gage Type Appraiser B
NAME
Characteristic Upper Specification Lower Specification Appraiser C

Second Analysis
EVALUATION CRITERIA
Measurement System False
Effectiveness Miss Rate
Decision Alarm Rate
Acceptable for the appraiser >90% <2% <5%

Marginally acceptable fo the

appraiser - may need >80% <5% <10%
improvement
Unacceptable for the
appraiser - needs <80% >5% >10%
improvement

RESULTS SUMMARY
False
Appraiser Effectiveness Miss Rate
Alarm Rate
A

Final Analysis

Approved for use as is

Not approved for use as is
Signature Title

Page 64 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2 2
3 3
4 AVE xa=
5 R ra=
6. B 1
7 2
8 3
9 AVE xb=
10 R rb=
11. C 1
12 2
13 3
14 AVE x c=
15 R rc=
16. PART X=
AVERAGE Rp=

17 (ra + rb + rc) / (# OF APPRAISERS) = R=

18 xDIFF = (Max x - Min x) = xDIFF=
19 * UCLR = R x D4 = UCLR=

* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.

Notes:
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Gage Type Appraiser C

Characteristic Classification Trials Parts Appraisers Date Performed

Measurement Unit Analysis % Total Variation (TV)

Repeatability - Equipment Variation (EV)
EV = R x K1 Trials K1 % EV = 100 (EV/TV)
= 2 0.8865 =
= 3 0.5907 =
Reproducibility - Appraiser Variation (AV)
AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/TV)
= =
= =
Appraisers 2 3
n = parts r = trials K2 0.7087 0.5236
Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/TV)
GRR = {(EV2 + AV2)}1/2 Parts K3 =
= 2 0.7087 =
= 3 0.5236
Part Variation (PV) 4 0.4464
PV = RP x K3 5 0.4032 % PV = 100 (PV/TV)
= 6 0.3745 =
= 7 0.3534 =
Total Variation (TV) 8 0.3378
TV = {(GRR2 + PV2)}1/2 9 0.3247 ndc = 1.41(PV/GRR)
= 10 0.3145 =
= =

For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2 2
3 3
4 AVE xa=
5 R ra=
6. B 1
7 2
8 3
9 AVE xb=
10 R rb=
11. C 1
12 2
13 3
14 AVE x c=
15 R rc=
16. PART X=
AVERAGE Rp=

17 (ra + rb + rc) / (# OF APPRAISERS) = R=

18 xDIFF = (Max x - Min x) = xDIFF=
19 * UCLR = R x D4 = UCLR=

* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.

Notes:
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Gage Type Appraiser C

Characteristic Classification Trials Parts Appraisers Date Performed

Measurement Unit Analysis % Tolerance (Tol)

Repeatability - Equipment Variation (EV)
EV = R x K1 Trials K1 % EV = 100 (EV/Tol)
= 2 0.8865 =
= 3 0.5907 =
Reproducibility - Appraiser Variation (AV)
AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/Tol)
= =
= =
Appraisers 2 3
n = parts r = trials K2 0.7087 0.5236
Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/Tol)
GRR = {(EV2 + AV2)}1/2 Parts K3 =
= 2 0.7087 =
= 3 0.5236
Part Variation (PV) 4 0.4464
PV = RP x K3 5 0.4032 % PV = 100 (PV/Tol)
= 6 0.3745 =
= 7 0.3534 =
Tolerance (Tol) 8 0.3378
Tol = Upper - Lower / 6 9 0.3247 ndc = 1.41(PV/GRR)
= ( Upper - Lower ) / 6 10 0.3145 =
= =

For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
ANOVA METHOD
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2 2
3 3
4 AVE xa=
5 R ra=
6. B 1
7 2
8 3
9 AVE xb=
10 R rb=
11. C 1
12 2
13 3
14 AVE xc=
15 R rc=
16. PART X=
AVERAGE Rp=

Anova Table
Source DF SS MS F Sig
Appraiser
Parts
Appraiser-by-Part
Equipment
Total
* Significant at a = 0.05 level

Page 69 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
ANOVA METHOD
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Standard
% Total Variation % Contribution
Anova Report Deviation (s)
Repeatability (EV)
Reproducibility (AV)
Appraiser by Part (INT)
GRR
Part-to-Part (PV)

Note:
Tolerance = Total variation (TV) =
Number of distinct data categories (ndc) =

Page 70 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE

TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2 2
3 3
4 AVE xa=
5 R ra=
6. B 1
7 2
8 3
9 AVE xb=
10 R rb=
11. C 1
12 2
13 3
14 AVE xc=
15 R rc=
16. PART X=
AVE ( Xp ) Rp=

Note: The REFERENCE VALUE can be substituted for PART AVE to generate graphs indicating true bias.

Page 71 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Average Chart -"Stacked"

12.00
10.00
8.00 Appraiser A
Average

Appraiser B
6.00
Appraiser C
4.00 Upper Spec
Lower Spec
2.00
0.00
1 2 3 4 5 6 7 8 9 10
Part Number

Analysis:

Range Chart -"Stacked"

12.00
10.00
8.00
Appraiser A
Range

6.00 Appraiser B
Appraiser C
4.00
Rucl
2.00
0.00
1 2 3 4 5 6 7 8 9 10
Part Number

Analysis:

Page 72 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Page 73 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Average Chart -"Unstacked"

12
10
8
Average

6
4
2
0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Appr A Appr B Appr C

Analysis:

Range Chart -"Unstacked"

12.000
10.000
8.000
Average

6.000
4.000
2.000
0.000
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Appr A Appr B Appr C

Analysis:

Page 74 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Page 75 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Run Chart
12

10

8
Value

0
1 2 3 4 5 6 7 8 9 10
Part

Analysis:

Page 76 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Scatter Plot
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Part 3
Part 1

Part 2

Part 4

Part 5
Scatter Plot
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Part 7

Part 8

Part 10
Part 6

Part 9

Analysis:

Page 77 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Whiskers Chart - Appraiser A

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10

Whiskers Chart - Appraiser B

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10

Whiskers Chart - Appraiser C

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10

Analysis:

Page 78 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Error Chart
12

10

0
Part 1

Part 2

Part 4

Part 5
Part 3

Error Chart
12

10

0
Part 6

Part 7

Part 8

Part 9

Part 10

Analysis:

Page 79 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Normalized Histogram - Error

1
0.9
0.8
0.7
0.6
0.5 Appr A
0.4
0.3
0.2
0.1
0
-1.00

-0.90

-0.80

-0.70

-0.20

-0.10

0.00

0.20

0.30

0.40

0.50

0.60

0.70
-0.60

-0.50

-0.40

-0.30

0.10

0.80

0.90

1.00
Normalized Histogram - Error
1
0.9
0.8
0.7
0.6
0.5 Appr B
0.4
0.3
0.2
0.1
0
-0.60

-0.50

-0.40

-0.30

-0.20

-0.10

0.00

0.10

0.20

0.30

1.00
-1.00

-0.90

-0.80

-0.70

0.40

0.50

0.60

0.70

0.80

0.90

Normalized Histogram - Error

1
0.9
0.8
0.7
0.6
0.5 Appr C
0.4
0.3
0.2
0.1
0
-1.00

-0.90

-0.80

-0.40

-0.30

-0.20

0.10

0.40

0.50

0.60

0.70

1.00
-0.70

-0.60

-0.50

-0.10

0.00

0.20

0.30

0.80

0.90

Analysis:

Page 80 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

XY Plot of Averages by Size

1.00

0.90

0.80

0.70
Appr A
0.60 Appr B
Appr C
0.50
X=Y line
0.40

0.30

0.20

0.10

0.00
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

Analysis:

Page 81 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Comparison XY Plot
1.00
0.90
0.80
0.70
0.60
Appr B

0.50
0.40
0.30
0.20
0.10
0.00
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Appr A

Comparison XY Plot
1.00
0.90
0.80
0.70
0.60
Appr C

0.50
0.40
0.30
0.20
0.10
0.00
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Appr A

Page 82 of 95
 0.90
0.80
0.70
GAGE
0.60 REPEATABILITY AND REPRODUCIBILITY DATA SHEET

Appr C
0.50 GRAPHICAL ANALYSIS
0.40
Part Number 0.30 Gage Name Appraiser A
NUMBER
Part Name
0.20 Gage Number Appraiser B
0.10NAME
Characteristic0.00 Specification Gage Type Appraiser C
Lower Upper
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Characteristic Classification Trials Parts Appraisers Date Performed
Appr A

Page 83 of 95
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
GRAPHICAL ANALYSIS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed

Comparison XY Plot
1.00
0.90
0.80
0.70
0.60
Appr C

0.50
0.40
0.30
0.20
0.10
0.00
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Appr B

Analysis:

Page 84 of 95
 VARIABLES CONTROL CHART ( x & R ) PART NO. CHART NO.
MEASUREMENT EVALUATION NUMBER
PART NAME (Product) OPERATION (Process) SPECIFICATION LIMITS
NAME
APPRAISER A APPRAISER B APPRAISER C MACHINE GAGE UNIT OF MEASURE ZERO EQUALS

x= UCL = LCL = AVERAGES (X BAR CHART)

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

r= UCL = LCL = RANGES (R CHART)

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

APPRAISER A APPRAISER B APPRAISER C

PART
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
NUMBER

R 1
E
2
A
D
3
I
N
4
G
S 5

SUM

SUM
x
NUM
 VARIABLES CONTROL CHART ( x & R ) PART NO. CHART NO.
MEASUREMENT EVALUATION NUMBER
PART NAME (Product) OPERATION (Process) SPECIFICATION LIMITS
NAME
APPRAISER A APPRAISER B APPRAISER C MACHINE GAGE UNIT OF MEASURE ZERO EQUALS

HIGH-
R
LOW

** = APPRAISER OUT OF CONTROL

Computations for the Control Chart Method of Evaluating a Measurement Process

REPLICATION ERROR: Average Subgroup Range = r = r d2
2 1.126
Number of replications = Subgroup Size = r = 3 1.693
4 2.059
Estimate Replication Standard Deviation r / d2 = se = 5 2.326

CALCULATION FOR APPRAISER EFFECT: Appraiser Averages

no d2* Number of Appraisers = nA = 0 Appraiser Average

2 1.410 A
3 1.906 Number of Samples = n = 0 B
C
Range of Appraiser Averages = RA = 0.00

Appraiser Effect = RA / d2* = sA =

CALCULATIONS FOR MEASUREMENT ERROR STANDARD DEVIATION:

sm = SQRT ( se + sA )

CALCULATIONS FOR SIGNAL TO NOISE RATIO: Sample Averages

no d2* Range for these Sample Averages = Rp = 0.00 Sample Average

2 1.410 1
3 1.906 Estimate Sample to Sample Standard Deviation: 2
4 2.237 3
5 2.477 sp = Rp / d2* = 4
6 2.669 5
7 2.827 Signal to Noise Ratio: 6
8 2.961 sp / sm = 7
9 3.076 8
10 3.178 9
10

Thus the number of distinct categories that can be reliably distinguished by these measurements is:

ndc = 1.41 x sp / sm =

This is the number of non-overlapping 97% confidence intervals that will span the range of product variation. (A 97% confidence
interval centered on a single measurement would contain the actual product value that is represented by that measurement 97%
of the time.)
 GAGE R STUDY PART NO. CHART NO.
MEASUREMENT EVALUATION NUMBER
PART NAME (Product) OPERATION (Process) ZERO EQUALS
NAME
APPRAISER MACHINE GAGE UNIT OF MEASURE UPPER SPECIFICATION LOWER SPECIFICATION

AVERAGES (X BAR CHART)

x= UCL = LCL =

12.00

10.00

8.00

6.00

4.00

2.00

0.00
1 2 3 4 5 6 7 8 9 10

RANGES (R CHART)
r= UCL = LCL =

1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10

READING 1 2 3 4 5 6 7 8 9 10

VALUE

HIGH-
R n/a 0 0 0 0 0 0 0 0 0
LOW

** = POINT OUT OF CONTROL

GAGE R ANALYSIS
Data in control? % Repeatability =

This method CANNOT be used for final gage acceptance without other complete and detailed MSA methods.
Bulk Materials Requirements Checklist Project:
Required / Primary Responsibility Comments / Approved
Target Date Customer Supplier Conditions by / date
Product Design and Development Verification

Design Matrix
Design FMEA
Special Product Characteristics
Design Records
Prototype Control Plan
Appearance Approval Report
Master Samples
Test Results
Dimensional Results
Checking Aids
Engineering Approval
Process Design and Development Verification

Process Flow Diagrams

Process FMEA
Special Product Characteristics
Pre-launch Control Plan
Production Control Plan
Measurement System Studies
Interim Approval
Product and Process Validation

Initial Process Studies

Part Submission Warrant
Elements to be Completed as Needed

Customer Plant Connection

Customer Specific Requirements
Change Documentation
Supplier Considerations

Plan agreed to by: Name / Function Company / Title / Date

 BULK MATERIAL INTERIM APPROVAL FORM

ORGANIZATION PRODUCT NAME:

ORGANIZATION NAME
(VENDOR) NAME:
ORGANIZATION ENG. SPEC.:
CODE
(VENDOR) CODE:
MANUF. SITE: CITY PART #:
ENG. CHANGE #: ECL FORMULA DATE:
RECEIVED DATE: RECEIVED BY:
SUBMISSION LEVEL: EXPIRATION DATE:
TRACKING CODE: RE-SUBMISSION DATE:

STATUS: (NR - Not Required, A - Approved, I - Interim)

Design Matrix DFMEA: Special Product Characteristics Engineering Approval
Control Plans PFMEA: Special Process Characteristics Process Flow Diagram
Test results Process Studies: Dimensional Results Master Sample
Measurement Systems Studies: Appearance Approval Report

SPECIFIC QUANTITY OF MATERIAL AUTHORIZED (IF APPLICABLE):

PRODUCTION TRIAL AUTHORIZATION #:
REASON(S) FOR INTERIM APPROVAL:

ISSUES TO BE RESOLVED, EXPECTED COMPLETION DATE

(CLASSIFY AS ENGINEERING, DESIGN, PROCESS, OR OTHER):

ACTIONS TO BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE DATE:

PROGRESS REVIEW DATE: DATE MATERIAL DUE AT PLANT:

WHAT ACTIONS ARE TAKING PLACE TO ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM
TO BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE?

SUPPLIER (AUTHORIZED SIGNATURE) PHONE:

(PRINT NAME) DATE:
CUSTOMER APPROVALS (as needed): PHONE: DATE:
PRODUCT ENG. (SIGNATURE)
(PRINT NAME)
MATERIALS ENG. (SIGNATURE)
(PRINT NAME)
QUALITY ENG. (SIGNATURE)
(PRINT NAME)
INTERIM APPROVAL NUMBER:
 PRODUCT / PROCESS CHANGE NOTIFICATION

Complete this form and e-mail to your customer organization whenever customer notification is required by
the PPAP Manual in Table 3.1. Your customer will respond back with an acknowledgement and may request
additional change clarification or PPAP submission requirements.

To: Customer: GM DIVISION

Organization Part Number: Engineering Revision Level: Dated:

Customer Part Number: NUMBER Engineering Revision Level: ECL Dated: ECL DATE
Purchase Order Number: Safety and/or Government Regulation:

Application: APPLICATION
ORGANIZATION MANUFACTURING INFORMATION

Name: ORGANIZATION Code: CODE

Street Address: ADDRESS
City, State, Zip: CITY STATE ZIP Change Type (check all that apply)
Dimensional
Customer Plants Affected: Materials
Functional
Design Responsibility: Customer Organization Appearance

Organization Change That May Affect End Item:

Product Change Engineering Drawing Change New or Revised Subcomponent

Expected PPAP Completion / Submission Date:

DETAILED DESCRIPTION OF PRODUCT / PROCESS CHANGE:

Planned Date of Implementation:

DECLARATION:
I hereby certify that representative samples will be manufactured using the revised product and/or process
and verified, where appropriate, for dimensional change, appearance change, physical property change,
functionally for performance and durability. I also certify that documented evidence of such compliance is on
file and available for customer review.

Explanation/Comments:

NAME: TITLE:

BUSINESS PHONE NO: FAX NO:

E-MAIL: DATE:

NOTE: Please submit this notification at least 6 weeks prior to the planned change implementation!

March THE-1220
2006
 Contact your customer to determine if this form is available in an electronic format or if this form should be faxed.

March THE-1220
2006
 Truck Industry Part Submission Warrant
Part Name NAME Customer Part Number NUMBER Rev.
If applicable
Tool PO Number Engineering Drawing Change Level ECL Dated

Additional Engineering Changes Dated

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

Checking Aid Number Engineering Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION

ORGANIZATION CODE GM DIVISION

Organization Name and Code Customer Name/Division

ADDRESS
Street Address Customer Contact

CITY STATE ZIP APPLICATION

City State Zip Application

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

Are plastic parts identified with appropriate ISO marking codes? Yes No

REASON FOR SUBMISSION

Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or Additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(check)
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer
drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular
production process. I also certify that documented evidence of such compliance is on file and available for review.

EXPLANATION/COMMENTS:

List Molds / Cavities / Production Processes

Organization Authorized Signature Date

Print Name Phone No. 555-555-5555 Fax No.

Title E-Mail

FOR CUSTOMER USE ONLY

PPAP Warrant Disposition: Approved Rejected
Interim Approval Comment:

Customer Signature Date

Print Name

March THE-1001
2006
 Part Submission Warrant
Part Name NAME Cust. Part Number NUMBER
Shown on Drawing Number Org. Part Number

Engineering Change Level ECL Dated ECL DATE

Additional Engineering Changes Dated

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

Checking Aid Number Checking Aid Eng. Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

ORGANIZATION CODE GM DIVISION

Supplier Name & Supplier/Vendor Code Customer Name/Division

ADDRESS
Street Address Buyer/Buyer Code

CITY STATE ZIP APPLICATION

City Region Postal Code Country Application

MATERIALS REPORTING

Has customer-required Substances of Concern information been reported? Yes No

Submitted by IMDS or other customer format:

Are polymeric parts identified with appropriate ISO marking codes? Yes No n/a
REASON FOR SUBMISSION (Check at least one)
Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all design record requirements: Yes NO (If "NO" - Explanation Required)
Mold / Cavity / Production Process

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all
Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production
rate of ____/____ hours. I also certify that documented evidence of such compliance is on file and available for your review. I have noted
any deviation from this declaration below.

EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered? Yes No n/a

Organization Authorized Signature Date

Print Name Phone No. 555-555-5555 Fax No.

Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)

PPAP Warrant Disposition:

Approved Rejected Other
Customer Signature Date

Print Name Customer Tracking Number (optional)

March CFG-1001
2006
 CUSTOMER LIST D/P FMEA LISTS M FMEA LISTS
ACTIVE # IN DOCUMENT 1 SEVERITY SCALE SEVERITY SCALE
1 GM 10 Hazardous - w/o warning 10 Hazardous - w/o warning
2 Ford Motor Company 9 Hazardous - w/ warning 9 Hazardous - w/ warning
3 DaimlerChrysler 8 Very High 8 Very High (Downtime - 8 hrs, Defects - 4
4 7 High 7 High (Downtime - 4-8 hrs, Defects - 2-4
5 6 Moderate 6 Moderate (Downtime - 1-4 hrs, Defects
6 5 Low 5 Low (Downtime - 0.5-1 hrs, Defects - 0-
7 4 Very Low 4 Very Low (Downtime - 10-30 min., 0 De
8 3 Minor 3 Minor (Downtime - 0-10 min., 0 Defects
9 2 Very Minor 2 Very Minor (0 Downtime, 0 Defects)
10 1 None 1 None
11 OCCURENCE SCALE OCCURENCE SCALE
12 10 >100 Per 1,000 10 1 in 1 hour, 1 in 90 cycles
13 9 50 Per 1,000 9 1 in 8 hours, 1 in 900 cycles
14 8 20 per 1,000 8 1 in 24 hour, 1 in 36,000 cycles
15 7 10 Per 1,000 7 1 in 80 hour, 1 in 90,000 cycles
16 6 5 Per 1,000 6 1 in 350 hour, 1 in 180,000 cycle
17 5 2 Per 1,000 5 1 in 1,000 hour, 1 in 270,000 cy
18 4 1 Per 1,000 4 1 in 2,500 hour, 1 in 360,000 cy
19 3 0.5 per 1,000 3 1 in 5,000 hour, 1 in 540,000 cy
20 2 0.1 Per 1,000 2 1 in 10,000 hour, 1 in 900,000 c
1 <0.01 Per 1,000 1 1 in 25,000 hour, 1 in >900,000
DETECTION SCALE DETECTION SCALE
10 Absolute Impossible 10 Absolute Impossible
9 Very Remote 9 Very Remote
8 Remote 8 Remote
7 Very Low 7 Very Low
6 Low 6 Low
5 Moderate 5 Moderate
4 Moderately High 4 Moderately High
3 High 3 High
2 Almost Certain 2 Almost Certain
1 Certain 1 Certain
 M FMEA LISTS
SEVERITY SCALE
10 Hazardous - w/o warning
9 Hazardous - w/ warning
8 Very High (Downtime - 8 hrs, Defects - 4 hrs)
7 High (Downtime - 4-8 hrs, Defects - 2-4 hrs)
6 Moderate (Downtime - 1-4 hrs, Defects - 1-2 hrs)
5 Low (Downtime - 0.5-1 hrs, Defects - 0-1 hrs)
4 Very Low (Downtime - 10-30 min., 0 Defects)
3 Minor (Downtime - 0-10 min., 0 Defects)
2 Very Minor (0 Downtime, 0 Defects)

OCCURENCE SCALE
10 1 in 1 hour, 1 in 90 cycles
9 1 in 8 hours, 1 in 900 cycles
8 1 in 24 hour, 1 in 36,000 cycles
7 1 in 80 hour, 1 in 90,000 cycles
6 1 in 350 hour, 1 in 180,000 cycles
5 1 in 1,000 hour, 1 in 270,000 cycles
4 1 in 2,500 hour, 1 in 360,000 cycles
3 1 in 5,000 hour, 1 in 540,000 cycles
2 1 in 10,000 hour, 1 in 900,000 cycles
1 1 in 25,000 hour, 1 in >900,000 cycles
DETECTION SCALE
10 Absolute Impossible
9 Very Remote
8 Remote
7 Very Low

5 Moderate
4 Moderately High

2 Almost Certain