List of PPAP documents

Sr No. Document Title Documents formats / templates Remarks

0 List of documents submitted List of documents Format provided

1 Design Records Bill Of Material Format provided

Drawings Drawings will be given by
Gates if applicable
Test Standards Format not provided
Engineering Change Documents Engineering Change Documents Format not provided -
approved document
2 received from Gates is
acceptable

Customer Engineering Approval Customer Engineering Approval Format not provided - any
approved document
3 received from Gates is
acceptable
Design FMEA Design FMEA Format provided (same as
4 AIAG format)

Process Flow Diagram Process Flow Chart (for Processing & Format provided
5
Assembly)
Process FMEA Process FMEA Format provided (same as
6 AIAG format)

7 Dimensional Results Dimensional Results Format provided

Material Performance Test Results Material Performance Test Results Format provided (Attach
8 your reports also)

Initial Process Study Control Chart (for stability) with Pp & Format provided
9
Ppk Calculation Sheet
10 Measurement System Analysis Studies MSA for variable characteristics Format provided
MSA for attribute characteristics Format provided

11 Qualified Laboratory Documentation Qualified Laboratory Documentation Format provided

Control Plan Control Plan Format not provided (to
12 comply with TS
requirements)

PSW PSW Format provided (same as

13
AIAG format)
Weight Calculation Sheet Format provided

14 Appearance Approval Report AAR Format provided

Bulk Material Requirements Checklist Bulk Material Requirements Checklist Format not provided
(depends on the specific
requirements - to be
15 discussed and agreed upon
with Gates before
submission)

16 Sample Product Sample Product Format not required

17 Master Sample Master Sample Format provided

18 Checking Aids Checking Aids List Format provided

Records of Compliance With Customer- List of approved TIER 2 suppliers Format provided
19
Specific Requirements
Special Process Qualification Records Format provided
 Packing procedure Packing procedure Attach photos of packed
20 parts
 List of documents submitted

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

PPAP Submission Level:

Applicable Submitted /
Sr No. Document Title Remarks
Y/N Retained
1 List of documents submitted
2 Design Records
Bill Of Material
Drawing
Test Standards
3 Engineering Change Documents
4 Customer Engineering Approval
5 Design FMEA
6 Process Flow Diagram
Overall Process Flow (for Assembly)
Process Flow Chart (for Feeder shop & Assembly)
7 Process FMEA
8 Dimensional Results
9 Material Performance Test Results
10 Initial Process Study
Control Chart
Pp, Ppk Calculation Sheet
11 Measurement System Analysis Studies
MSA for variable characteristics
MSA for attribute characteristics
12 Qualified Laboratory Documentation
13 Control Plan
14 PSW
Weight Calculation Sheet
15 Appearance Approval Report
16 Bulk Material Requirements Checklist
17 Sample Product
18 Master Sample
19 Checking Aids
20 Records of Compliance With Customer-Specific
Requirements
List of approved TIER 2 suppliers
Process Qualification Records

Prepared by Date

Checked by Date

Approved by Date
 Bill Of Material

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Made In-house /
Sr No. Part Number Part Name Level Qty Name of TIER2 Remarks
Supplier

Prepared by Date

Checked by Date

Approved by Date
 Potential failure mode and effects analysis (Design FMEA)
System: Design responsibility: FMEA Number:
Subsystem: Key date: Page:
Component: Model year(s) / Vehicle(s) : Prepared by:
Part no:
Core team: FMEA date (Orig) : (Rev)
Potential Current Current ACTION RESULTS
Potential Responsibility &
Potential failure cause(s) / design design
Item / Function effect(s) of Recommended actions target completion

Detect
Action

Occur
Class
mode mechanism(s) of controls controls

RPN

RPN
failures date

Occ
taken

Sev

Sev

Det
failure prevention detection
 PROCESS FLOW DIAGRAM PAGE: OF
REV:-
MODEL :- PART NO:- PART NAME:- DATE:-

OPN. PROCESS
OPERATION MACHINE PROCESS CHARACTERISTICS PRODUCT CHARACTERISTICS
NO. FLOW

PREPARED BY CHECKED BY APPROVED BY

OPERATION INSPECTION TRANSPORT DELAY STORAGE OPERATION & INSPECTION AT A TIME
 Audit week
num ber
7 11 15 20 24 29 33 37 42 47 51 02 POTENTIAL
Revis ion
Updated by
FAILURE MODE AND EFFECTS ANALYSIS FMEA Number :
Reviewed by
Page :- of
Process
Item : Responsibility :- Prepared By :-

Project/Program: Key Date :- FMEA Date (Orig) :- (Rev.) :

Core Team :-

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

Part Name: Part No. & Rev: Page of Pages

Supplier Name: Plant Location:

Stage of the Trials (Proto / Before Mass Production / Mass Production / Others - Pl specify):

Observation Result
Sl No Dimension / Specification Class Instrument USL LSL Remarks
1 2 3 4 5 OK / NOK

Prepared by Date

Checked by Date

Approved by Date
 Material Test Results

Part Name: Part No. & Rev: Page of Pages

Supplier Name: Plant Location:

Stage of the Trials (Proto / Before MP / Mass Production / Others - Pl specify): Name of Laboratory:

Material Specification no. & Type of Observation Result

Sl No Class USL LSL Remarks
details test 1 2 3 4 5 OK / NOK
Prepared by Date

Checked by Date

Approved by Date
 Performance Test Results

Part Name: Part No. & Rev: Page of Pages

Supplier Name: Plant Location:

Stage of the Trials (Proto / Before MP / Mass Production / Others - Pl specify): Name of Laboratory:

Test Qty Observations Test Conditions Result

Sl No Requirements Class USL LSL Remarks
Freq Tested 1 2 3 4 5 OK / NOK

Prepared by Date

Checked by Date

Approved by Date
 GAGE REPEATABILITY AND REPRODUCIBILITY GAGE REPEATABILITY AND REPRODUCIBILITY
DATA COLLECTION SHEET REPORT

Part Number Gage Name Appraiser A Part Number Gage Name Appraiser A
MSA 3rd edition example XXXX A MSA 3rd edition example XXXX A
Part Name Gage Number Appraiser B Part Name Gage Number Appraiser B
XXXX XXXX B XXXX XXXX B
Characteristic/Specification Gage Type Appraiser C Characteristic/Specification Gage Type Appraiser C
XXXX XXXX C XXXX XXXX C
Total Tolerance Trials Parts Appraisers Date Performed Total Tolerance Trials Parts Appraisers Date Performed
0 3 10 3 12/3/2008 0 3 10 3 12/3/2008

APPRAISER/ PART AVERAGE Measurement Unit Analysis

TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)
1. A 1 0.29 (0.56) 1.34 0.47 (0.80) 0.02 0.59 (0.31) 2.26 (1.36) 0.1940 % Total Variation % Tolerance
2 2 0.41 (0.68) 1.17 0.50 (0.92) (0.11) 0.75 (0.20) 1.99 (1.25) 0.1660 EV = R x K1 Trials K1
3 3 0.64 (0.58) 1.27 0.64 (0.84) (0.21) 0.66 (0.17) 2.01 (1.31) 0.2110 = 0.3417 x 0.5908 2 0.8862 % EV = 100 (EV/TV) % EV = 100 (EV/TOL)
4 AVE 0.447 -0.607 1.260 0.537 -0.853 -0.100 0.667 -0.227 2.087 -1.307 Xa= 0.1903 = 0.20186 3 0.5908 = 100(0.202/1.146)
5 R 0.35 0.12 0.17 0.17 0.12 0.23 0.16 0.14 0.27 0.11 Ra= 0.1840 Reproducibility - Appraiser Variation (AV) = 17.61 = #DIV/0!
6. B 1 0.08 (0.47) 1.19 0.01 (0.56) (0.20) 0.47 (0.63) 1.80 (1.68) 0.0010
7 2 0.25 (1.22) 0.94 1.03 (1.20) 0.22 0.55 0.08 2.12 (1.62) 0.1150 AV = {(XDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/TV) % AV = 100 (AV/TOL)
8 3 0.07 (0.68) 1.34 0.20 (1.28) 0.06 0.83 (0.34) 2.19 (1.50) 0.0890 = {(0.4447 x 0.5231)^2 - (0.2019 ^2/(10 x 3))}^1/2 = 100(0.230/1.146)
9 AVE 0.133 -0.790 1.157 0.413 -1.013 0.027 0.617 -0.297 2.037 -1.600 Xb= 0.0683 = 0.22967 Appraisers 2 3 = 20.04 = #DIV/0!
10 R 0.18 0.75 0.40 1.02 0.72 0.42 0.36 0.71 0.39 0.18 Rb= 0.5130 K2 0.7071 0.5231
11. C 1 0.04 (1.38) 0.88 0.14 (1.46) (0.29) 0.02 (0.46) 1.77 (1.49) -0.2230 Repeatability & Reproducibility (R & R) n = number of parts n = number of parts
12 2 (0.11) (1.13) 1.09 0.20 (1.07) (0.67) 0.01 (0.56) 1.45 (1.77) -0.2560 r = number of trials r = number of trials
13 3 (0.15) (0.96) 0.67 0.11 (1.45) (0.49) 0.21 (0.49) 1.87 (2.16) -0.2840 R&R = {(EV2 + AV2)}1/2 Parts K3
14 AVE -0.073 -1.157 0.880 0.150 -1.327 -0.483 0.080 -0.503 1.697 -1.807 Xc = -0.2543 = {(0.202^2 + 0.230^2)}^1/2 2 0.7071
15 R 0.19 0.42 0.42 0.09 0.39 0.38 0.20 0.10 0.42 0.67 Rc= 0.3280 = 0.30577 3 0.5231 % R&R = 100 (R&R/TV) % R&R = 100 (R&R/TOL)
16. PART X= 0.0014 Part Variation (PV) 4 0.4467 = 100(0.306/1.146)
AVE ( Xp ) 0.169 -0.851 1.099 0.367 -1.064 -0.186 0.454 -0.342 1.940 -1.571 Rp= 3.5111 5 0.4030 = 26.68 = #DIV/0!
17 (Ra + Rb + Rc) / (# OF APPRAISERS) = R= 0.3417 PV = RP x K3 6 0.3742
18 (Max X - Min X) = XDIFF= 0.4447 = 3.511 x 0.3146 7 0.3534 % PV = 100 (PV/TV) % PV = 100 (PV/TOL)
19 R x D4* = APPRAISER B OUT OF CONTROL UCLR= 0.8815 = 1.10460 8 0.3375 = 100(1.105/1.146)
Total Variation (TV) 9 0.3249 = 96.38 = #DIV/0!
10 0.3146
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are TV = {(R&R2 + PV2)}1/2 ndc = 1.41(PV/GRR)
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or = {(0.306^2 + 1.105^2)}^1/2 = 1.41(1.10460/0.30577)
discard values and re-average and recompute R and the limiting value from the remaining observations. = 1.14613 = 5.094 5

Based on data catagories, gauge system is Acceptable

Notes: This is an example of study shown in MSA 3rd Edition manual (Page 113)
All the observed readings in Bracket are negative values. may be acceptable based upon importance of application, cost of
Based on Total Variation, gauge system
measurement device, cost of repair, etc.

Based on Tolerance, gauge system #DIV/0!

ONLY CHANGE AREAS THAT ARE SHADED BLUE

 Page 15 Gauge R&R-Data sheet(Variable)

Data Sheet for R&R ( Variability type) Study

All entries in pen only. Attach hard copy / scanned copy of this sheet to MSA report
Gauge/Inst No. Part No. : Date :
Description : Part Name: Location:

Range : Parameter: Appraiser A:

Least Count : Spec. : Appraiser B:

Make : Tolerance: Appraiser C:

Appraiser Measured Values

Trials 1 2 3 4 5 6 7 8 9 10
1

A :- 2

B :- 2

C :- 2

Before R& R study ensure the following conditions :

I 1.Select the components from different batch / Lot / Shift.

2.Only calibrated instrument to be used.
3.Select instrument with correct discrimination.

II 1.Don't change the measuring point.

2.Don't change the place of the equipment .
3.Don't change the method.
4.Don't change the Instrument.

Comments if any: Study Approved

conducted by :-
by:
 ATTRIBUTE MSA - HYPHOTHESIS TEST

NOTE:
(ENTER THE DATA ONLY IN YELLOW CELLS) DATE: 05.12.2008
PART NAME :- XXXX GAUGE NAME: XXX

PART NO. :- xxxx GAUGE NO: XXX

MSA STUDY DETAILS : For Inner Diameter 10.2mm

Note: OK NOT OK OBSERVER:-

1 0
APPRIASER A - Subash B - Iyyapan AGREEMENT / DISAGREEMENT
PART MASTER REF. A1 A2 B1 B2 A1-B1 A2-B2 A1-Ref A2 - Ref B1-Ref B2-Ref
1 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
2 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
3 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
4 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
5 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
6 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
7 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
8 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
9 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
10 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
11 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
12 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
13 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
14 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
15 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
16 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
17 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
18 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
19 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
20 1 1 1 1 1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1 YES 1-1
Agreement Yes 1-1 20 20 20 20 20 20
Yes 0 - 0 0 0 0 0 0 0
Disagreement NO 0 -1 0 0 0 0 0 0
No 1-0 0 0 0 0 0 0

Cross -tabulation comparision

Cross -tabulation comparision - A-B

B
Total
0 1
A 0 Count 0 0 0
Expected Count 0.000 0.00 0.0
1 Count 0 40 40
Expected Count 0.00 40.0000 40.0

Total Count 0 40 40

Expected Count 0.0 40.0 40.0

Cross -tabulation comparision - A - Ref.

Ref
Total
0 1
A 0 Count 0 0 0
Expected Count 0.000 0.0 0.0
1 Count 0 40 40
Expected Count 0.00 40.000 40.0
Total Count 0 40 40
Expected Count 0.0 40.0 40.0

Cross -tabulation comparision - B- Ref.

Ref
Total
0 1
B 0 Count 0 0 0
Expected Count 0.0 0.0 0.0
1 Count 0 40 40
Expected Count 0.00 40.0 40.0
Total Count 0 40 40
Expected Count 0.0 40.0 40.0
 po− pe
Kappa=
1− pe
Let po = The sum of the observed proportions in the diagonal cells.
Pe = The sum of the expected proportion in the diagonal cell

Kappa measures for appraisers :

Kappa B Remarks Accptance Criteria for Kappa

A 0.00 Kappa :
Kappa : 1 - Excellent agreement
Greater than 0.75 - Good agreement
Less than 0.40 - Poor agreement
Kappa measures for appraisers to reference decision :
Remarks :
A B

Kappa 0.00 0.00

Remarks

GAUGE STATUS NOTOK

IMPROVEMENT DETAILS FOR NOT OK GAUGE: (TICK MARK IN RELEVENT BOX.)

A) GAUGE DESIGN NOT CORRECT:- RE-LOOK THE GAUGE DESIGN

B) METHOD OF USING GAUGE AMONG 2 APPRAISERS IS DIFFERENT

STANDARDISE THE CHECKING METHOD

C) GAUGE USAGE CRITERIA NEED TO BE DEFINED

Checked by :- Approved by:-

 Data Sheet for R&R (Attribute type ) Study

Gauge / Inst Number : Date :

Gauge / Inst Description : Location :
Part No : Parameter :
Part Name : Spec :
Assesor A : Assesor B :
Reference value Reference
Parts TRIAL 1 TRIAL 2 TRIAL 1 TRIAL 2 Code (+ or -)
(Compt dimn) (1 or 0)
1 or 0 1 or 0 1 or 0 1 or 0

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

1 - GOOD + Perfect agreement for all appraisers wrt Reference value (For GOOD)
0- NOT GOOD - Perfect agreement for all appraisers wrt Reference value (For NOT GOOD)
X Poor agreement between appraisers wrt Reference value
Before measurement ensure the following condition :

I 1.Select the components from different batch / Lot / Shift

( Also ensure that the components are selected to its Min/Middle/Max size/Closer to USL&LSL )

II 1.Don't change the place of the component.

2.Don't change the method
3.Don't change the Gauge / Instrument.
Assessor -A Assessor -B Checked By : Approved By :
 Week:
X-bar / R chart - Process Performance study Month: Dec.
Year: 2007
Part / Dimension details Enter Data / Values in green colour boxes only. Other cells are protected.
Part: Cover Clutch Sub-group details n --> 2 3 4 5 Values obtained Process Capability/Performance
Drawing No. N xxxxxxx Rev. b Sub-groupNo.of sub D4 3.27 2.57 2.28 2.11 X= 14.0258 Standard Deviation:
Parameter: Dome Centre Height size groups D3 0.00 0.00 0.00 0.00 R- 0.1672 s 0.0719 s 0.0787
Dimension: 14.00 +/- 0.40 n N A2 1.88 1.02 0.73 0.58 UCLX= 14.1477 Process Capability/Performance:
USL 14.400 d2 1.13 1.69 2.06 2.33 LCLX= 13.9039 Cp 1.85 Pp 1.69 PROCESS
4 25 CAPABLE
LSL 13.600 E2 2.66 1.77 1.46 1.29 UCLR- 0.3816 Cpk 1.74 Ppk 1.59

Sub-group 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
X1 14.000 14.070 14.020 13.870 14.000 13.890 14.000 14.140 13.990 13.990 14.020 14.130 14.010 14.120 14.140 13.870 14.150 13.940 13.850 14.130 14.070 13.890 13.990 14.120 13.940
X2 14.120 14.010 14.010 14.070 13.980 14.120 13.880 14.080 14.010 14.010 13.980 14.060 13.970 14.080 13.930 13.950 14.110 13.900 14.030 14.120 14.010 14.120 14.010 14.080 13.900
X3 14.090 13.900 13.990 14.090 14.030 14.140 14.130 14.050 14.130 14.020 13.980 14.090 14.130 13.960 14.130 14.010 13.990 14.010 14.080 14.080 13.900 14.140 14.020 13.960 14.010
X4 14.110 14.090 14.010 13.990 14.120 13.940 13.950 14.020 14.020 13.960 14.010 13.890 13.990 14.010 14.060 14.080 13.920 14.130 14.090 14.120 14.090 13.940 13.960 14.010 14.130
X-Bar 14.080 14.018 14.008 14.005 14.033 14.023 13.990 14.073 14.038 13.995 13.998 14.043 14.025 14.043 14.065 13.978 14.043 13.995 14.013 14.113 14.018 14.023 13.995 14.043 13.995
Range 0.120 0.190 0.030 0.220 0.140 0.250 0.250 0.120 0.140 0.060 0.040 0.240 0.160 0.160 0.210 0.210 0.230 0.230 0.240 0.050 0.190 0.250 0.060 0.160 0.230
Date 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Time 8.45 9.00 9.15 9.30 9.45 10.00 10.15 10.30 10.45 11.00 11.15 11.30 11.45 12.00 12.15 12.30 12.45 13.00 13.15 13.30 13.45 14.00 14.15 14.30 14.45

X-bar X=
UCLX= LCLX= X-bar Chart
14.2000
14.1500
Values

14.1000
14.0500
14.0000
13.9500
13.9000
13.8500
13.8000
13.7500
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
Sub-group No.

Range Av. Range Range Chart

Range values

0.4500
0.4000
0.3500
0.3000
0.2500
0.2000
0.1500
0.1000
0.0500
0.0000
Subgroup No.
 Week:
X-bar / R chart - Process Performance study Month: Dec.
Year: 2007
Part / Dimension details Enter Data / Values in green colour boxes only. Other cells are protected.
Part: Cover Clutch Sub-group details n --> 2 3 4 5 Values obtained Process Capability/Performance
Drawing No. N xxxxxxx Rev. b Sub-groupNo.of sub D4 3.27 2.57 2.28 2.11 X= 14.0298 Standard Deviation:
Parameter: Dome Centre Height size groups D3 0.00 0.00 0.00 0.00 R- 0.1750 s 0.0752 s 0.0789
Dimension: 14.00 +/- 0.40 n N A2 1.88 1.02 0.73 0.58 UCLX= 14.1308 Process Capability/Performance:
USL 14.400 d2 1.13 1.69 2.06 2.33 LCLX= 13.9288 Cp 1.77 Pp 1.69 PROCESS
5 20 CAPABLE
LSL 13.600 E2 2.66 1.77 1.46 1.29 UCLR- 0.3700 Cpk 1.64 Ppk 1.56

Sub-group 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
X1 14.000 14.070 14.020 13.870 14.000 13.890 14.000 14.140 13.990 13.990 14.020 14.130 14.010 14.120 14.140 13.870 14.150 13.940 13.850 14.130
X2 14.120 14.010 14.010 14.070 13.980 14.120 13.880 14.080 14.010 14.010 13.980 14.060 13.970 14.080 13.930 13.950 14.110 13.900 14.030 14.120
X3 14.090 13.900 13.990 14.090 14.030 14.140 14.130 14.050 14.130 14.020 13.980 14.090 14.130 13.960 14.130 14.010 13.990 14.010 14.080 14.080
X4 14.120 13.950 14.020 13.920 14.080 14.110 14.150 14.070 14.080 13.980 13.950 13.950 14.110 14.170 14.120 13.900 14.040 14.050 13.950 13.970
X5 14.110 14.090 14.010 13.990 14.120 13.940 13.950 14.020 14.020 13.960 14.010 13.890 13.990 14.010 14.060 14.080 13.920 14.130 14.090 14.120
X-Bar 14.088 14.004 14.010 13.988 14.042 14.040 14.022 14.072 14.046 13.992 13.988 14.024 14.042 14.068 14.076 13.962 14.042 14.006 14.000 14.084
Range 0.120 0.190 0.030 0.220 0.140 0.250 0.270 0.120 0.140 0.060 0.070 0.240 0.160 0.210 0.210 0.210 0.230 0.230 0.240 0.160
Date 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Time 10.00 10.15 10.30 10.45 11.00 11.15 11.30 11.45 12.00 12.15 12.30 12.45 13.15 13.15 13.30 13.45 14.00 14.15 14.30 14.35

X-bar X=
UCLX= LCLX= X-bar Chart
14.1500
14.1000
Values

14.0500
14.0000
13.9500
13.9000
13.8500
13.8000
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

Sub-group No.

Range Av. Range Range Chart

0.4000
0.3500
0.3000
0.2500
0.2000
0.1500
0.1000
0.0500
0.0000
 Quality Laboratory Documentation

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Laboratory : Internal / External Laboratory Name:

Characteristics / Test Equipment Next Calibration Due
Sr No. Class Specs Type of Test Working Range R&R Value Calibration Date Test Standard Used Remarks
Requirement used on

Prepared by Date

Checked by Date

Approved by Date
 PART SUBMISSION WARRANT

Part Name ________________________________________________________ Part Number ___________________________

Safety and/or Engineering Drawing Change Level______________________________ Dated ______________

Govt Regulation Yes No

Additional Engineering Changes __________________________________________________________ Dated ______________

Shown On Drawing No.__________________ Purchase Order No_______________________________ Weight(kg) __________

Checking Aid No. __________________________ Engineering Change Level _________________________ Dated ______________

Supplier Manufacturing Information Submission Information

______________________________________________
Supplier Name & Supplier code Dimensional Materials/Functional Appearance
Address:
______________________________________________ Customer Name/Division _______________________________________

______________________________________________ Buyer/Buyer Code _____________________________________________

______________________________________________ Application ___________________________________________________

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

Are plastic parts identified with appropriate ISO marking code Yes No

Reason For Submission

Initial Submission Change to optional construction or material

Engineering Change 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 Others-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 supplier's manufacturing location.

Submission Results
The results for dimensional measurements material and functional tests appearance criteria statistical process package

These results meet all drawing and specification requirements : Yes No (if "No" Explanation Required)

Mold /Cavity/Production process:_____________________________________________

Declaration

I here by affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval
Process Manual 3rd edition requirements .I further warrant these samples were produced at the production rate of ______ /8 hours.I have noted any deviations
from this declaration below.

Explanation/Comments:__________________________________________________________________________________________

Print Name:___________________ Title:________________ Phone No._____________________ Fax No.______________________

Supplier Authorized Signature_______________________________________________________ Date:________________________

For Customer Use Only (if applicable)

Part Warrant Disposition: Approved Rejected Part Function Approval: Approved

Other Waived
Customer Name ____________________________________ Customer Signature _______________________ Date ______________
 Appearance Approval Report
Part Name - Supplier Name
Finished part number
Rev no and date - Supplier Code

Semifinished part number Manufacturing Plant Location

Rev no and date -
AAR Rev no and date

Master Status Approval Status

Specs / Results /
# Description Required / Master Remarks
Reqts Actuals
Not Validation
Required Frequency Approved Rejected
1 Material source approval
Base material
Paint
Sticker
Source
Grade

2 Surface and texture evaluation

Texture ID
Texture source
Texture location on the part

3 Material, Colour and Gloss evaluation

Gloss
DOI
Metallic Brilliance
Colour

4 Ornamentation and graphics

Plating
Logo
Stickers

5 Other appearance defects

a) Press & Fabrication related
Weld bead appearance
Surface dents / damages
Deformation
Spatters
Blow Holes

b) Painting / Plating / Powder Coating related

Orange peel
Shade variation
Paint rundown
Peel Off

c) Rubber / Plastics related

Flashes
Patches
Ejector pin marks
Parting line
Scratches
Deformation
Dust accumulation
Foggy appearance ( for transparent parts)

d) Casting and Forging related

Flashes
Ejector pin marks
Die catch marks
Pre finish surface

Note - Additional requirements may be included in the above sections

Approval Signatures

Supplier representative

GUIC Quality
 Product Weight Details

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Weight in Kgs (upto 3

Sr No. Remarks
decimels)

10

Average

Prepared by Date

Checked by Date

Approved by Date
 Master Sample Identification Card
Part Name
Part Number
Rev No. & Date
Date of PSW Approval
Printing Identification Details
Sample Identification Details
Project Reference
Storage Location
Validity date

Approved by

Supplier Head Quality GUIC Quality

Date Date
 List of Checking Aid

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Characteristics / Checking Checking Aid

Checking Aid Checking Aid
Sr No. Specification / Aid used Drawing Rev No R&R details Remarks
Name Number
Requirement (Attr/Var) & Date

Prepared by Date

Checked by Date
Approved by Date
 List of TIER 2 Suppliers

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Fully Bought Name of

Part / Raw Material Name out (or) Name of the Name of the TIER 2 Certification (ISO Certification Whether GUIC
Sr No. Part / Material Number Remarks
(with reference to BOM) Partially outsourced process Supplier TS 16949 / ISO Validity Date approved?
Outsourced 9001)

Prepared by Date

Checked by Date

Approved by Date
 Special Process Qualification Record (Sheet 1)

Section 1 : Part Details Page of Pages

Part Name: Part No. & Rev:

Supplier Name: Plant Location:

Section 2 : Special Processes Details

Names of the Special Processes involved (Eg. Welding, Soldering, Brazing, Painting, Plating, Heat treatment, Crimping, etc.)

Name of the Special Details of Machine / Operator & Inspector

Sr No. Process Parameters USL LSL Remarks
Process Equipment Used Names

Prepared by Date

Checked by Date

Approved by Date
 Special Process Qualification Record (Sheet 2)
Section 3 : Experiment Details
Result
Name of the Name of the Result (OK /
Sr No. Process Parameters Set Value Product Parameters Record Remarks
Special Process Experiment NOK)
Reference
1 SP1 LSL experiment Process Parameter 1 SV 1 Parameter Specs Actuals
Process Parameter 2 SV 2 Product Parameter 1 Lsl - Usl A1 OK Annex 1
Process Parameter 3 SV 3 Product Parameter 2 Lsl - Usl A2 OK Annex 2
Process Parameter 4 SV 4 Product Parameter 3 Lsl - Usl A3 OK Annex 3
Process Parameter 5 SV 5 Product Parameter 4 Lsl - Usl A4 OK Annex 4

USL Experiment Process Parameter 1 SV 6 Product Parameter 1 Lsl - Usl A5 OK Annex 5

Process Parameter 2 SV 7 Product Parameter 2 Lsl - Usl A6 OK Annex 6
Process Parameter 3 SV 8 Product Parameter 3 Lsl - Usl A7 OK Annex 7
Process Parameter 4 SV 9 Product Parameter 4 Lsl - Usl A8 OK Annex 8
Process Parameter 5 SV 10

2 SP2 LSL experiment Process Parameter 1 SV 1 Parameter Specs Actuals

Process Parameter 2 SV 2 Product Parameter 1 Lsl - Usl A1 OK Annex 1
Process Parameter 3 SV 3 Product Parameter 2 Lsl - Usl A2 OK Annex 2
Process Parameter 4 SV 4 Product Parameter 3 Lsl - Usl A3 OK Annex 3
Process Parameter 5 SV 5 Product Parameter 4 Lsl - Usl A4 OK Annex 4

USL Experiment Process Parameter 1 SV 6 Product Parameter 1 Lsl - Usl A5 OK Annex 5

Process Parameter 2 SV 7 Product Parameter 2 Lsl - Usl A6 OK Annex 6
Process Parameter 3 SV 8 Product Parameter 3 Lsl - Usl A7 OK Annex 7
Process Parameter 4 SV 9 Product Parameter 4 Lsl - Usl A8 OK Annex 8
Process Parameter 5 SV 10

3 SP3 LSL experiment Process Parameter 1 SV 1 Parameter Specs Actuals

Process Parameter 2 SV 2 Product Parameter 1 Lsl - Usl A1 OK Annex 1
Process Parameter 3 SV 3 Product Parameter 2 Lsl - Usl A2 OK Annex 2
Process Parameter 4 SV 4 Product Parameter 3 Lsl - Usl A3 OK Annex 3
Process Parameter 5 SV 5 Product Parameter 4 Lsl - Usl A4 OK Annex 4

USL Experiment Process Parameter 1 SV 6 Product Parameter 1 Lsl - Usl A5 OK Annex 5

Process Parameter 2 SV 7 Product Parameter 2 Lsl - Usl A6 OK Annex 6
Process Parameter 3 SV 8 Product Parameter 3 Lsl - Usl A7 OK Annex 7
Process Parameter 4 SV 9 Product Parameter 4 Lsl - Usl A8 OK Annex 8
Process Parameter 5 SV 10

Prepared by Date

Checked by Date

Approved by Date