Professional Documents
Culture Documents
What is PPAP?
Production Part Approval Process Standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAGs 4th edition effective June 1, 2006 is the most recent version PPAP has now spread to many different industries beyond automotive
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Purpose of PPAP
Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate
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Production Run
Production process
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Run @ Rate
The purpose of a Run @ Rate is to verify the suppliers manufacturing process is capable of producing components that meet NCRs quality requirements, at quoted tooling capacity, for a specified period of time Verification of the Run @ Rate will be at the Supplier Quality Engineers (SQE) discretion. The supplier will be notified of the need to perform a Run @ Rate as early in the process as possible. The number of components to be produced during the Run @ Rate should be sufficient to demonstrate process capability and will be predetermined by the SQE and the supplier.
Factors such as product complexity, shelf life, storage, cost and single shift vs. multiple shift operations will be taken into consideration
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10. Records of Material / Performance Test Results 11. Initial Process Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR) 14. Sample Production Parts 15. Master Sample 16. Checking Aids 17. Customer-Specific Requirements 18. Part Submission Warrant (PSW)
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10. Records of Material / Performance Test Results 11. Initial Process Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR) 14. Sample Production Parts 15. Master Sample 16. Checking Aids 17. Customer-Specific Requirements 18. Part Submission Warrant (PSW) NCR calls this the Production Warrant
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Supplier shall submit these 12 items and retain a copy of records at appropriate locations
10. Records of Material / Performance Test Results 11. Initial Process Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR) 14. Sample Production Parts 15. Master Sample 16. Checking Aids 17. Customer-Specific Requirements 18. Part Submission Warrant (PSW) NCR calls this the Production Warrant
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Supplier shall retain these 6 items at appropriate locations, and make readily available upon request
Level 1
Level 2 Level 3 Level 4
Production Warrant and Appearance Approval Report (if applicable) submitted to NCR Production Warrant, product samples, and dimensional results submitted to NCR Production Warrant, product samples, and complete supporting data submitted to NCR Production Warrant and other requirements as defined by NCR
Level 5
Production Warrant, product samples and complete supporting data (a review will be conducted at the supplier's manufacturing location)
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* = Supplier shall retain at appropriate locations, and submit to NCR upon S = Supplier shall request. NCR will submit to NCR & retain identify what is needed a copy of records or for submission. documentation items at appropriate locations R = Supplier shall retain at appropriate locations and make readily available to NCR upon request
S = The supplier shall submit to NCR and retain a copy of records or documentation items at appropriate locations. R = The supplier shall retain at appropriate locations and make readily available to NCR upon request. * = The supplier shall retain at appropriate locations, and submit to NCR upon request. NCR will identify what is needed for submission.
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Definition of Risk
High Risk
Parts associated with multiple critical features, complex design, or high end technology that is not yet established in the general manufacturing environment Suppliers quality system and/or quality performance is not to NCR satisfaction
Medium Risk
Parts that have at least one critical feature
Low Risk
Parts that have no critical features and can be manufactured by any manufacturer in the commodity category Suppliers quality system and quality performance are acceptable
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Part Changes
Level 3 is required for Parts produced at a new or additional location Supplier Quality Excellence will define the level required for all other changes NCR reserves the right to redefine the submission level required
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PPAP Status
Approved
The part meets all NCR requirements Supplier is authorized to ship production quantities of the part
Interim Approval
Permits shipment of part on a limited time or piece quantity basis
Rejected
The part does not meet NCR requirements, based on the production lot from which it was taken and/or accompanying documentation
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NCR requires that all PPAPs be submitted electronically Use of paper submission must have prior approval by the SQE Submission must be received on or prior to the PPAP due date Review and Approval Process:
NCR will attempt to review and provide feedback within 2 business days
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PRODUCTION WARRANT
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Production Warrant
Production Warrant
Part Name Shown on Drawing no. Engineering Drawing Change Level Additional Engineering Changes Safety and/or Government Regulation Checking Aid No. SUPPLIER MANUFACTURING INFORMATION Supplier Name Supplier Code Yes No Purchase order No. Engineering Change Level NCR Part Number Supplier Part Number Dated Dated Weight (kg) Dated
What is It?
Buyer Code
Document required for all newly tooled or revised products in which the supplier confirms that inspections and tests on production parts show conformance to NCR requirements
Does this part contain any restricted or reportable substances? Are parts identified with appropriate UL/CE/ISO marking codes if applicable?
REASON FOR SUBMISSION Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one based on NCR requirements) Level 1 Level 2 Level 3 Level 4 Level 5 Production Warrant and Appearance Approval Report (if applicable) submitted to NCR Production Warrant, product samples, and dimensional results submitted to NCR Production Warrant, product samples, and complete supporting data submitted to NCR Production Warrant and other requirements as defined by NCR Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part processing Parts Produced at New or Additional Location Other - please specify
Objective or Purpose
Used to : document part approval provide key information declare that the parts meet specification
SUBMISSION RESULTS The results for dimensional measurements material and functional tests Yes No appearance criteria (If "No" - Explanation Required) statistical process package
These results meet all drawing and specification requirements: Mold / Cavity / Production Process: DECLARATION
When to Use It
I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all of NCR's Production Part Approval Process requirements. I further affirm that these samples were produced at the production rate of _____ pieces / _____ hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS:
Supplier Authorized Signature Print Name Email Title Phone No. FOR CUSTOMER USE ONLY (IF APPLICABLE) PPAP Warrant Disposition: NCR Signature Print Name _____ NCR Tracking Number (optional) Approved Rejected Other
Date
____________________________________________________ Date
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Production Warrant
Production Warrant
Part Name Shown on Drawing no. Engineering Drawing Change Level Additional Engineering Changes NCR Part Number Supplier Part Number Dated Dated
Part Name / NCR Part Number Safety and/or Government Regulation Yes No Purchase order No. Weight (kg) Engineering released finished Shown on Drawing Number Supplier Part Number Engineering Change Level & Date end part name and number Checking Aid record No. Engineering Change Level Dated The design thatitem specifies Part number defined Show the change level and date of by the customer part number being the supplier, if any INFORMATION SUPPLIER MANUFACTURING INFORMATION NCR SUBMITTAL the Design Record submitted Additional Engineering Changes Supplier Name Supplier Code NCR Location Safety and/or Government Regulation List all authorized Engineering Purchase Order Number Yes if so indicated by the Design Record, changes not yet incorporated in Enter this number as found on Street Address Buyer otherwise No Buyer Code the design record but which are the contract / purchase order Checking Aid Number, Change Level, & Date incorporated in the part City Region Postal Code Country Model Name / Number Enter if requested by the customer
Note:
Does this part contain any restricted or reportable substances? Are parts identified with appropriate UL/CE/ISO marking codes if applicable?
Yes Yes
No No
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Production Warrant
Production Warrant
Part Name NCR Part Number Supplier Part Number Dated Dated Purchase order No. Weight (kg)
Supplier Manufacturing Information Shown on Drawing no. Show the name and code assigned to Engineering Drawing Change Level the manufacturing site on the Additional order Engineering purchase /Changes contract
Safety and/or Government Regulation Yes No
Parts Identified with Appropriate Marking Codes Checking No. Engineering Change Level Dated UL = Aid Underwriters Laboratories safety standards CE = Conformite Europeenne (European Conformity) SUPPLIER MANUFACTURING INFORMATION NCR SUBMITTAL INFORMATION Certifies that a product has met European consumer NCR Location Restricted Substances Safety, health, or environmental requirements NCR Location Supplier Name Supplier Code Show the location where Enter Yes or No ISO = International Organization for Standardization Buyer / Buyer Code to parts will be shipped Enter Yes or Nothe buyers name Street Address Buyer Enter Model Name / Number and code the model name City Region Enter Postal Code Country Model Name / Number and number
Note:
Does this part contain any restricted or reportable substances? Are parts identified with appropriate UL/CE/ISO marking codes if applicable?
Buyer Code
Yes Yes
No No
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Production Warrant
Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year
Requested Submission Level Identify the submission level REQUESTED SUBMISSION LEVEL (Check one based on NCR requirements) Mold / Cavity / Production Process requested by NCR Level 1 - parts Production Warrant and Appearance Approval Report (if applicable) submitted to NCR If production will be produced from Level 2 one - Production product samples, and dimensional results submitted to NCR more than mold,Warrant, cavity, tool, die, pattern, or process, the and supplier Level 3 production - Production Warrant, product samples, complete supporting data submitted to NCR Submission Results shall complete a dimensional evaluation on Check the appropriate Level 4 - Production Warrant and other requirements as defined by NCR boxes one part from each. The specific molds, Level 5 - Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location lines, etc. shall then be identified here.
SUBMISSION RESULTS The results for dimensional measurements material and functional tests Yes No appearance criteria (If "No" - Explanation Required) statistical process package
These results meet all drawing and specification requirements: Mold / Cavity / Production Process:
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Production Warrant
Declaration Declaration Explanation / Comments Affirmation that the samples represented Entercomments the number of pieces Provide any explanatory on the by the during warrant are representative and manufactured the submission results or any deviations Supplier Authorized Signature were made by run a process that meets NCRs significant production from the Declaration. Attach additional A DECLARATION responsible supplier official, after verifying requirements and the PPAP time (in hours) taken information as appropriate. that the results show conformance to all NCR for the significant production run I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all of NCR's requirements and that all required documentation Production Part Approval Process requirements. I further affirm that these samples were produced at the production rate of is _____ available, shall declaration pieces / _____ hours. Iapprove also certify that the documented evidence of such compliance is on file and available for review. I have noted
any deviations from this declaration below.
For NCR Use Only To be completed by appropriate PPAP Warrant Disposition NCR Supplier Quality Engineer NCR Signature Approved, Rejected, Other Supplier Authorized Signature Signed by NCR Supplier Print Name Title Quality Engineer
EXPLANATION/COMMENTS: Email FOR NCR USE ONLY PPAP Warrant Disposition: NCR Signature Print Name _____ NCR Tracking Number (optional) Approved Rejected Other Phone No.
Date
____________________________________________________ Date
The approved Production Warrant officially warrants the parts ready for production
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Production Warrant
Reviewers Checklist
Must be completely filled out Must be signed by the supplier P/N must match the PO Submitted at the correct revision level Submitted at the correct submission level Specify the reason for submission
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Specifications
Feasibility
Supplier
studies
Sub-assembly
Life
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No
A visual diagram of the entire process from receiving through shipping, including outside processes and services
Operator Remove Small Plies from the Cutting Table (36) Small Plies Operator Cutting Operation Complete (34)
Objective or Purpose
Operator Move Plies to Kitting Table (41) Traveler Complete? (42) Yes Operator Stamp Traveler (43)
Operator Large Tag while Laying Large or Small Plies Piies on the Cutting or Test Coupons? Table And (35) (39) Coupons
Project Idea
Fill Out Master Form with Initial Information Other Required Signatures: Segment CEO Champion Process Owner BB or GB Other Required Signatures: Champion: Process Owner Project Owner Dept GB/BB/MBB
Get WO Assigned
No
Finance Approval and Signature No Do you have BB/GB to Assist/Work the project? Yes
To help people see the real process. Process maps can be used to understand the following characteristics of a process: Set-by-step process linkage Offline activities (measurement, inspection, handling) Rework, scrap
Master Form Will Generate Contract Yes Is Hard Savings > $???
6 Sigma Project
No
Does the Project Involve Only Your Group? Finance Approval and Signature No
Yes
When to Use It
Other Required Signatures: Champion: Dir T&E Process Owner Project Owner Dept BB or MBB
No
Other Required Signatures: Champion: Dir T&E Process Owner Project Owner Dept BB or MBB
Close Project
Yes
No
Close Project
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Fabrication
STEP
Operation Description
Inspect
Item #
Item #
Move
Store
Control Methods
1 2 3 4 5 6 7 8 9 10 11 12
The process flow diagram utilizes these symbols to clearly identify each step in the process
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F/QA/05/0
: NCR : 1 of 1
: PFD/NCR/0264 : O / 10.08.09
Final Isnpection 20
Patrol Insp. report Oiling, Packing & Preservation 50 Layout Inspection 40 Pre delivery Inspection 30
Not ok , Rejected
**
Inspection as per RIQP If Rejected
If rework possible
Rework
100% Re-inspection
Return to supplier
Not ok , Rejected Note : Tags to be provided for OK, Rework, Inspection & Rejection
Not ok Scrap
Ok Next operation
- STORAGE - INSPECTION
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Star Exercise
Using the instructions handed out in class, make 10 Shuriken Stars This exercise will prepare your team to complete future exercises
45 Minutes
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Cutting
Tucking
05
10
15
20
Patrol Insp Report
25
30
Shipping
Packing
40
35
If rework possible
Rework
100% Inspection OK
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Process Flow must identify each step in the process Should include abnormal handling processes
Scrap Rework
Assembly
Shipping
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PROCESS FMEA
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What is It?
Responsibility & Target Com pletion Date Action Results O S c e c v u r D e t e c R. P. N.
S e v
O c c u r
D e t e c
R. P. N.
ActionsTaken
A tool used to identify and prioritize risk areas and their mitigation plans.
Objective or Purpose
Identifies potential failure modes, causes, and effects. Inputs come from the process flow diagram. Identifies key inputs which positively or negatively affect quality, reliability and safety of a product or process.
After completion of the process flow diagram. Prior to tooling for production
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FMEA Origin
Created by NASA following Apollo 1 mission failure Allows us to take a proactive approach to what can go wrong in a process and manage our risks better
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Process Step
R.P.N.
Occur
Detec
Class
Sev
R.P.N.
Actions Taken
Occ
Sev
Det
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PFMEA - Step 1
Potential Potential Failure Modes Cause(s)/ Effect(s) of Mechanism(s) For each Process Input, Failure of Failure
R.P.N.
Occur
Detec
Class
Process Step
Current Process Controls Variables check for film thickness; Visual check for coverage
Op 70: Manual Insufficient wax Allows integrity 7 inputManually which the can go application of coverage over breach wrong. of inner inserted spray wax inside door specified surface door panel head not panel inserter far Corroded interior enough lower door panels
Sev
5 280
Using the completed Process Flow Diagram, enter the process step.
Deteriorated life of door leading to: - Unsatisfactory appearance due to rust through paint over time - Impaired function of interior door hardware
Spray head clogged: - Viscosity too high - Temp too low - Pressure too low
5 Variables check for film thickness; Visual check for coverage; Test spray at start-up and after idle periods and preventative maintenance program to clean heads
5 175
TIPS There should be at least one failure mode for each input.
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PFMEA - Step 2
Potential Effect(s) of Failure Potential Cause(s)/ Mechanism(s) of Failure
R.P.N.
Occur
Detec
Class
Process Step
Sev
7
Op 70: Manual Insufficient wax Allows integrity application of coverage over breach of inner wax inside door specified surface door panel panel Corroded interior lower door panels Deteriorated life of door leading to: - Unsatisfactory appearance due to rust through paint over time - Impaired function of interior door hardware
For each Failure Mode, determine what effect the specific failure Spray head 5 Variables check 5 175 could have on the clogged: for film process output. - Viscosity too thickness; Visual
high - Temp too low - Pressure too low check for coverage; Test spray at start-up and after idle periods and preventative maintenance program to clean heads
Manually 8 Variables check 5 280 inserted spray for film head not thickness; Visual inserter far check for Potential Failure Effects enough coverage
TIPS
There should be at least one failure effect for each failure mode. Effects should be specific, clear, and leave no doubt to the uninformed reviewer.
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PFMEA - Step 3
Potential Cause(s)/ Mechanism(s) of Failure Manually inserted spray head not inserted far enough
Process Step
R.P.N.
Occur
Detec
Class
Current Process Controls Variables check for film thickness; Visual check for coverage
Sev
7
Op 70: Manual Insufficient wax Allows integrity application of coverage over breach of inner wax inside door specified surface door panel panel Corroded interior Potential Causes lower door For each Failure Mode,panels
5 280
of door leading to: - Unsatisfactory appearance due to rust through paint over time - Impaired function of interior door hardware
Spray head clogged: - Viscosity too high - Temp too low - Pressure too low
5 Variables check for film thickness; Visual check for coverage; Test spray at start-up and after idle periods and preventative maintenance program to clean heads
5 175
TIPS
There should be at least one potential cause for each failure mode.
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PFMEA - Step 4
Potential Effect(s) of Failure Potential Cause(s)/ Mechanism(s) of Failure
R.P.N.
Occur
Detec
Class
Process Step
Current Process Controls Variables check for film thickness; Visual check for coverage
Op 70: Manual Insufficient wax Allows integrity 7 Manually application of coverage over breach of inner inserted spray wax inside door specified surface door panel head not Current Controls panel inserter far For each potential Corroded interior enough lower door cause, list the current panels method used for Spray head preventing or detecting Deteriorated life clogged: failure.
TIPS
This step in the FMEA current control plan. If a procedure exists,
5 Variables check 5 175 for film of door leading - Viscosity too thickness; Visual to: high check for - Unsatisfactory - Temp too low coverage; Test appearance due - Pressure too spray at start-up to rust through low and after idle paint over time periods and - Impaired preventativeor gaps in begins to identify initial shortcomings function of maintenance interior door program to clean hardware heads enter the document number.
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Sev
5 280
the
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PFMEA - Step 5
Assign Severity, Occurrence, and Detection ratings
Process Step Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/ Mechanism(s) of Failure
R.P.N.
Occur
Detec
Class
Sev
Op 70: Manual Insufficient wax Allows integrity (How serious is the application effect of coverage over breach of inner if it fails?) wax inside door specified surface door panel panel Corroded interior lower door panels
Assign Severity
Manually 8 Variables check inserted spray for film headDetection not thickness; Visual Assign inserter far can the check for (How easily enough coverage cause or failure
5 280
mode be detected?)
Spray head Deteriorated life Assign Occurrence clogged: of door leading (How likely is the - Viscosity too to: cause to occur?) high - Unsatisfactory - Temp too low appearance due - Pressure too to rust through low paint over time - Impaired function of interior door hardware
5 Variables check for film thickness; Visual check for coverage; Test spray at start-up and after idle periods and preventative maintenance program to clean heads
5 175
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Occurrence
Very high and almost inevitable High repeated failures
Detection*
Cannot detect or detection with very low probability Remote or low chance of detection
High
10
Low
No effect
Create a rating system that makes sense for the defects you are trying to prevent.
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PFMEA - Step 6
Potential Cause(s)/ Mechanism(s) of Failure
Process Step
R.P.N.
Occur
Detec
Class
Op 70: Manual Insufficient wax Allows integrity 7 Manually 8 Variables check application of coverage over breach of inner inserted spray for film wax inside door specified surface door panel head not thickness; Visual panel inserter far check for Corroded enough Calculate theinterior Risk Priority Number coverage lower door RPN = Severity x Occurrence x Detection panels Deteriorated life of door leading to: - Unsatisfactory appearance due to rust through prioritize the most paint over time - Impaired function of above) are flags interior door to hardware Spray head clogged: - Viscosity too high - Temp too low - Pressure too critical risks low
Sev
5 280
TIPS
The RPN is used to of the FMEA.
take effort
5 Variables check 5 175 for film thickness; Visual check for coverage; Test spray at start-up identified in the first half and after idle periods and preventative maintenance to reduce the calculated program to clean heads
Regardless of RPN, high Severity scores (9 or 10) should be given special attention.
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Sort the FMEA by the RPN numbers. Graphical and statistical tools can help the team select a cut-off RPN for the next steps.
RPN Thresholds When using an RPN threshold, DO NOT forget to address high Severity scores
Pareto Chart
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removes or controls a cause. Examples are redundancy, substituting a more reliable component or function or mistake-proofing.
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FMEA Step 7
Determine Actions Recommended to reduce High RPNs
Action Results Process Step Potential Failure Mode Potential Effect(s) of Failure
Op 70: Manual Insufficient wax Allows integrity 280 Add positive application of coverage over breach of inner depth stop to wax inside door specified surface door panel sprayer panel Automate Corroded interior spraying For the high RPN numbers, lower door determine the panels
R.P.N.
Recommended Responsibility & Actions Target Date Mfg. Eng. By 5/10/10 Mfg. Eng. By 5/25/10
R.P.N.
Occ
Sev
Det
Actions Taken
recommended actions.
Deteriorated life of door leading to: - Unsatisfactory appearance due to rust through paint over time - Impaired function of interior door hardware
Stop added, 7 2 5 70 sprayer checked on-line Rejected due to complexity of different doors on the same line Temp and press 7 1 5 35 limits were determined and limit controls have been installed - Control charts show process is in control Cpk = 1.85
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Assign a specific person who will responsible Insufficient wax be Allows integrity 280 Add positive coverage over breach of inner depth stop to for recommended actions.
Stop added, 7 2 5 70 sprayer checked door panel sprayer on-line Automate Mfg. Eng. By Rejected due to Corroded interior spraying 5/25/10 complexity of Actions lower door Taken different doors on panels As actions are identified the same line 175 Use document DOE on Mfg. Eng. By Temp and press 7 1 5 35 and completed, Deteriorated life viscosity vs. 5/31/10 limits were the Actions Taken of in door leading temp vs. determined and to: column. pressure limit controls - Unsatisfactory have been appearance due installed - Control to rust through charts show SEV, OCC, DET, RPN paint over time process is in - Impaired As actions are control complete Cpk = function of 1.85 reassess Severity, interior door Occurrence, and Detection hardware
Continue updating the actions taken and resulting RPNs until all risks are at an acceptable level (below 125).
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R.P.N.
R.P.N.
Occ
Sev
Det
Actions Taken
10. Revisit steps 7 and 8 until all the significant RPNs have been addressed.
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PFMEA Exercise
Instructions Open the PPAP Training Templates.xls file, then select the PFMEA worksheet. Using process steps 20 and 25 from the completed Star Process Flow Diagram handout, complete 2 rows of the PFMEA.
30 Minutes
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Material concerns
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CONTROL PLAN
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Control Plan
What is It?
A document that describes how to control the critical inputs to continue to meet customer expectations of the output.
Objective or Purpose
Primary reference source for minimizing process and product variation. Description of how teams should react to out-of-control situations.
NOTE
Since processes are expected to be continuously updated and improved, the control plan is a living document!
When to Use It
Implementation of new process Following a process change
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Control Plan
Tool Interaction
Project Idea
Process Step
S O E Potential Causes C V C Inadequate staffing in mail 7 room Customer or bank did not include name and/or 10 account info on wire transfer Customer error 5
Current Controls
D E T
R P N
E O C
Actions Recommended
Resp.
Actions
Fill Out Master Form with Initial Information Other Required Signatures: Segment CEO Champion Process Owner BB or GB Other Required Signatures: Champion: Process Owner Project Owner Dept GB/BB/MBB
Get WO Assigned
No
Process Steps
Receive Payment
None 7 10 490
Investigate mail room G. Lee staffing and associated processes Poka-Yoke wire transer N. Peart process
Finance Approval and Signature No Do you have BB/GB to Assist/Work the project? Yes
Identify Customer
Master Form Will Generate Contract Yes Is Hard Savings > $???
5 250
6 Sigma Project
No
Does the Project Involve Only Your Group? Finance Approval and Signature No
Yes
Other Required Signatures: Champion: Dir T&E Process Owner Project Owner Dept BB or MBB
No
Other Required Signatures: Champion: Dir T&E Process Owner Project Owner Dept BB or MBB
Close Project
Yes
No
Close Project
Customer might catch it when reviewing the 5 next statement 10 250 Acct identifies problem when trying to apply 10 payment 5 250
Provide payment stub A. Lifeson with statement for each invoice Provide payment stub S. Hagar with statement for each invoice
Invoice number Invoice shows not supplied outstanding (AR balance does go down)
Customer error 5
Process Flowchart
Process FMEA
Control Plan
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CONTROL PLAN
Prototype Control Plan Number Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code Pre-Launch Production Key Contact/Phone Core Team Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class Date:(Org.) Date (Rev.)
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
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Control Plan
3 Distinct Phases
CONTROL PLAN
Prototype Control Plan Number Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code Pre-Launch Production Key Contact/Phone Core Team Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class Date:(Org.) Date (Rev.)
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
3 Distinct Phases 3 Distinct Phases 3 Distinct Phases 2.description Pre-Launch 3. the Production a description a of comprehensive the 1. Prototype a of dimensionaland measurements documentationand of product/process dimensional measurements material and performance characteristics, tests process that controls, material and performance tests that occur after tests, Prototype and measurement and before systems that will occur duringwill Prototype build. full Production will . occur during mass production
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Control Plan
Administrative Section
CONTROL PLAN
Prototype Control Plan Number Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code Pre-Launch Production Key Contact/Phone Core Team Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class Date:(Org.) Date (Rev.)
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
Administrative Section Identifies part number and description, supplier, required approval signatures, and dates.
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Control Plan
Process, Machine/Tools, Characteristics
CONTROL PLAN
Prototype Pre-Launch Use this area to define Control Plan Number part/process number and description. Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code
Part/Process
Define Production
Key Contact/Phone Core Team
Characteristics
Date:(Org.)
Date (Rev.)
Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
List the machine, device, jig, or tools that will be used in the manufacturing process
Machine/Tools
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Control Plan
Specifications, Measurement, Sample Size & Frequency
What is the size of the sample you should gather data from?
Sample Size
CONTROL PLAN
Prototype Control Plan Number Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code
Use this area to define upper/lower spec limits for each Core Teamcontrol element.
Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class
Pre-Launch
Production
Date:(Org.)
Date (Rev.)
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
For each line in the control plan, list the measurement procedure that will be used (may list R&R Gage Plan or PokaYoke).
Measurement Technique
Frequency
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Control Plan
Control Method, Reaction Plan
Control Method
CONTROL PLAN
Prototype Control Plan Number Part Number/Latest Change Level Part Name/Description Supplier/Plant Supplier Code Pre-Launch Production Key Contact/Phone Core Team Supplier/Plant Approval/Date Other Approval/Date (If Req'd.) Characteristics No. Product Process Special Char. Class
Date:(Org.)
Date (Rev.)
Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods Sample Evaluation Product/Process /Measure Specification/ ment Size Freq. Tolerance Technique
Machine, Process Part/Process Device, Name/Operation Number Jig, Tools, Description for MFG.
Control Method
Reaction Plan
Reaction Plan
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Control Plan
Audit Plans
Audit plans should be included in the control plan as a separate line. Auditing is an important tool for control. Process auditing should be a key element of the quality system of a business. Audits generally cover:
Effectiveness of controls
Audits should be objective (done by internal or external third parties if possible). Audit frequencies should be based on balancing level of risk (FMEA) and cost.
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Product = inspection Product =Automated 100% Product = Continuous Process = x-MR chart Process = 1 pc Process = 4 hours
Date:(Org.) Date retest (Rev.) Product = Adjust and 11/29/2009 2/20/2010 Process = Segregate and retest Customer Engineering Approval/Date (If Req'd.) Customer Quality Approval/Date(If Req'd.) Other Approval/Date (If Req'd.) Methods
Reaction Plan
Product/Process Evaluation / Specification/ Measurement Tolerance Technique Sensor continuity check Test sampling lab environment
Reaction Plan
Soldering Connections
Flux Product = Sensor continuity check concen Process = Test sampling lab environment tration
Measurement Technique
100%
Standard #302B
1 pc
4 hours
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Document potential problems that might be encountered and potential solutions with your teams.
20 Minutes
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Control Plan
Use process flow diagram and PFMEA to build the control
plan; keep them aligned
Reviewers Checklist
Keep it simple.
Ensure that the control plan is in the document control Good control plans address:
All testing requirements - dimensional, material, and performance All product and process characteristics at every step throughout the process
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IMPORTANT!
Measurement System Analysis is an analysis of the measurement process, not an analysis of the people!!
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Unless approved by an NCR SQE, attribute data is not acceptable for PPAP submission
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The observed variation in process output measurements is not simply the variation in the process itself; it is the variation in the process plus the variation in measurement that results from an inadequate measurement system.
Observed Variation
Process Variation
Conducting an MSA reduces the likelihood of passing a bad part or rejecting a good part
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Observed Variation
Process Variation
Observed Variation
Accuracy
(Central Location)
Bias Stability
Process Variation
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Resolution
Precision Repeatability Reproducibility
Linearity
Observed Variation
Bias
Stability
Process Variation
Resolution
Error in Resolution
The inability to detect small changes.
Possible Cause
Wrong measurement device selected - divisions on scale not fine enough to detect changes.
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Repeatability
Error in Repeatability
The inability to get the same answer from repeated measurements made of the same item under absolutely identical conditions.
Possible Cause
Lack of standard operating procedures (SOP), lack of training, measuring system variablilty.
Equipment Variation
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Reproducibility
Error in Reproducibility
The inability to get the same answer from repeated measurements made under various conditions from different inspectors.
Possible Cause
Appraiser Variation
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Gage R&R is the combined estimate of measurement system Repeatability and Reproducibility Typically, a 3-person study is performed
Each person randomly measures 10 marked parts per trial Each person can perform up to 3 trials
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Number of operators Number of trials Number of samples Data Sample # 1 2 3 4 5 6 7 8 9 10 Range average Sample average 1 Operator 1 Trial 2 3
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 #DIV/0!
Operator 2 Trial 2 3
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 #DIV/0!
Operator 3 Trial 2 3
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 #DIV/0!
0.000 #DIV/0!
Repeatability (EV) Reproducibility (AV) Repeatability and Reproducibility (R&R) Control limit for individual ranges
Note: any ranges beyond this limit may be the result of assignable causes. Identify and correct. Discard values and recompute statistics.
Do not modify this table Trials D4 K1 K2 2 3.27 4.56 3.65 3 2.58 3.05 2.7
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1. 2. 3.
Select 10 items that represent the full range of long-term process variation. Identify the appraisers. If appropriate, calibrate the gage or verify that the last calibration date is valid.
4.
5. 6. 7. 8. 9.
Open the Gage R&R worksheet in the PPAP Playbook to record data.
Have each appraiser assess each part 3 times (trials first in order, second in reverse order, third random). Input data into the Gage R&R worksheet. Enter the number of operators, trials, samples and specification limits Analyze data in the Gage R&R worksheet. Assess MSA trust level.
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Step 1
variation.
Identify the appraisers.
Should use individuals that actually do the process being tested. Can also include other appraisers (supervisors, etc.). Should have a minimum of 3 appraisers.
Step 2
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Step 3
Step 4
Open the Gage R&R worksheet in the PPAP Playbook to record the data
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Step 5
After each appraiser completes the first evaluation of all items repeat the process at least 2 more times.
Do not let the appraisers see any of the data during the test !!
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Step 6
Step 7
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Step 8
Step 9
30% 10%
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Step 10
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MSA Process
MSA Parameters
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This spreadsheet is designed for up to three operators, three trials, and ten samples. Enter data ONLY in gray shaded cells.
Number of operators Number of trials Number of samples Data Sample # 1 2 3 4 5 6 7 8 9 10 Range average Sample average 1 25.250 25.420 22.370 24.960 25.540 24.610 24.440 26.100 25.390 25.680
Operator 1 Operator 2 Operator 3 Trial Trial Trial 2 3 Range 1 2 3 Range 1 2 3 Range 25.540 25.390 0.290 25.390 25.390 25.390 0.000 25.680 26.330 26.520 0.840 25.540 24.960 0.580 25.540 25.520 25.470 0.070 26.380 26.130 25.960 0.420 22.370 22.670 0.300 22.220 22.180 22.220 0.040 22.670 22.810 22.670 0.140 25.250 25.110 0.290 25.110 25.680 25.920 0.810 25.680 26.200 25.540 0.660 25.540 25.820 0.280 25.540 25.680 25.680 0.140 25.730 25.960 25.890 0.230 25.110 24.820 0.500 24.960 26.700 25.110 1.740 25.390 25.540 25.960 0.570 24.260 24.110 0.330 25.250 25.540 25.420 0.290 25.250 25.830 25.390 0.580 26.800 26.100 0.700 25.540 25.540 25.820 0.280 25.110 25.680 25.920 0.810 25.390 25.390 0.000 26.380 26.660 26.220 0.440 25.250 25.540 25.390 0.290 25.820 25.540 0.280 23.900 25.250 25.110 1.350 24.200 23.870 22.960 1.240 0.355 0.516 0.578 25.043 25.211 25.248
Repeatability (EV) Reproducibility (AV) Repeatability and Reproducibility (R&R) Control limit for individual ranges
Note: any ranges beyond this limit may be the result of assignable causes. Identify and correct. Discard values and recompute statistics.
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Number of operators Number of trials Number of samples Data Sample # 1 2 3 4 5 6 7 8 9 10 Range average Sample average 1 25.250 25.420 22.370 24.960 25.540 24.610 24.440 26.100 25.390 25.680
3 3 10
27 22
Operator 1 Operator 2 Operator 3 Trial Trial Trial 2 3 Range 1 2 3 Range 1 2 3 Range 25.540 25.390 0.290 25.390 25.390 25.390 0.000 25.680 26.330 26.520 0.840 25.540 24.960 0.580 25.540 25.520 25.470 0.070 26.380 26.130 25.960 0.420 22.370 22.670 0.300 22.220 22.180 22.220 0.040 22.670 22.810 22.670 0.140 25.250 25.110 0.290 25.110 25.680 25.920 0.810 25.680 26.200 25.540 0.660 25.540 25.820 0.280 25.540 25.680 25.680 0.140 25.730 25.960 25.890 0.230 25.110 24.820 0.500 24.960 26.700 25.110 1.740 25.390 25.540 25.960 0.570 24.260 24.110 0.330 25.250 25.540 25.420 0.290 25.250 25.830 25.390 0.580 26.800 26.100 0.700 25.540 25.540 25.820 0.280 25.110 25.680 25.920 0.810 25.390 25.390 0.000 26.380 26.660 26.220 0.440 25.250 25.540 25.390 0.290 25.820 25.540 0.280 23.900 25.250 25.110 1.350 24.200 23.870 22.960 1.240 0.355 0.516 0.578 25.043 25.211 25.248 Tolerance analysis 29.46% 9.65% 31.00%
Average range = 0.483 Repeatability (EV) 1.4732 Repeatability (EV) Reproducibility = (AV) X-bar range 0.205 Reproducibility (AV) 0.4827 Equipment Variation Repeatability and Reproducibility (R&R) 1.5502 Repeatability & Appraiser Variation Control limit for individual ranges 1.2461 Reproducibility = R&R Note: any ranges beyond this limit may be the result
of assignable causes. Identify and correct. Discard values and recompute statistics.
Determine roles.
(3) inspectors, (1) data recorder, (1) customer
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Dimension
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4. Repeat Step 3 with the 2nd inspector 5. Repeat Step 3 with the 3rd inspector 6. Round 2 Change the inspection to reverse order and repeat. 7. Round 3 Change the inspection to random order and repeat.
Use the file PPAP Training Templates.xls
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% Tolerance*
30%
10%
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MSA
Reviewers Checklist
Make sure the study is recent - less than 1 year Compare the control plan gages against the Gage R&Rs
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DIMENSIONAL RESULTS
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Dimensional Results
FAI Non-Critical Dimensions
Date: Part Number: Revision: Supplier Name: Facility Location: Supplier Code: Date Code: Inspected By: Verified By:
What is It?
Evidence that dimensional verifications have been completed and results indicate compliance with specified requirements.
The number of non-critical data points required for part qualification is 5. The non-critical data points must be taken from the same 35-piece sample as the critical data points. Five parts from a production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts are being shipped. Non-critical dimensional results for the 5 parts being shipped must be entered below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The supplier should make every effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions. Cpk less than 1.33 will require action for improvement
Print zone or spec note
Nominal Value
Tol +
Tol -
Cp #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Cpk #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Pass/Fail
Objective or Purpose
To show conformance to the customer part print on dimensions and all other noted requirements.
When to Use It
For each unique manufacturing process (e.g., cells or production lines and all molds, patters, or dies
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Nominal Value
Tol +
Tol -
10
11
12
13
14
15
The number of critical data points required for part qualification is 35. production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts are being shipped. Critical dimensional results for the 5 parts being shipped must be entered below. Non-critical dimensional results must be entered into the "FAI Non-Critical Dimensions" worksheet. The supplier should make every effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions.
Automatically These data points must be taken from a 35-piece sample. Five parts from a Calculates Cpk!
Sample
18 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Cp #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
The number of critical data points required for part qualification is 35. These data points must be taken from a 35-piece sample. Five parts from a production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts are being shipped. Critical dimensional results for the 5 parts being shipped must be entered below. Non-critical dimensional results must be entered into the "FAI Non-Critical Dimensions" worksheet. The supplier should make every effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions.
Cpk #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Pass/Fail
Requires 35 data points Cpk must be greater than or equal to 1.67 This is included in the PPAP Playbook!
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The number non-critical data points required for qualification is 5. The non-critical data points must be of taken from the same 35-piece sample as the critical data points. Fivepart parts from a production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to must beverify taken from the same 35-piece sample as the critical data both critical and non-critical dimensions. The supplier must clearly identify which of the 35 partspoints. Five parts from a production are being shipped. Non-critical dimensional results for the 5 parts being shipped must be entered run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The supplier should make every effort to ship 5 parts that represent both theThe low and high ends of the verify both critical and non-critical dimensions. supplier must clearly identify which of the 35 parts specifications for the non-critical dimensions. are being shipped. Non-critical dimensional Cpk less than 1.33 will require action for results improvement for the 5 parts being shipped must be entered Automatically Nominal Tol + Tol - Sample 1 Sample 2 Sample 3 be Sample 4 Sample 5 Cp Cpk "FAI Pass/Fail below. CriticalValue dimensional results must entered into the Critical Dimensions" worksheet. The #DIV/0! #DIV/0! Calculates Cpk! #DIV/0! supplier should make every effort to ship 5 parts that#DIV/0! represent both the low and high ends of the #DIV/0! #DIV/0! Requires 5 data points #DIV/0! #DIV/0! specifications for the non-critical dimensions.
Print zone or spec note
The number of non-critical data points required for part qualification is 5. The non-critical data points
#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
#DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
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Acceptance Criteria
Non-Critical
<1.00 1.00-1.33 >1.33
Decision
Cpk must be greater than or equal to 1.67 for critical processes Cpk must be greater than or equal to 1.33 for non-critical processes
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The number of non-critical data points required for part qualification is 5. The non-critical data points must be taken from the same 35-piece sample as the critical data points. Five parts from a production run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts Cp & be Cpk are being shipped. Non-critical dimensional results for the 5 parts being shipped must entered Nominal Value Tolerance Sample Data Pass / Fail below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The Calculations supplier should make every effort to ship 5 parts that represent both the low and high ends of the specifications for the non-critical dimensions. Cpk less than 1.33 will require action for improvement
Print zone or spec note
Nominal Value 35 76 3 3 3 3
Tol - Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 0.50 34.86 34.78 34.88 34.86 34.82 0.50 75.96 76.08 75.92 75.93 76.09 0.50 3.175 3.18 3.156 3.168 3.178 0.50 3.18 3.156 3.178 3.175 3.18 0.50 3.18 3.175 3.174 3.18 3.156 0.50 3.156 3.18 3.173 3.175 3.18
Cpk Pass/Fail 2.833 Pass 2.001 Pass 11.250 Pass 10.703 Pass 11.011 Pass 11.034 Pass
Dimensional Results
Reviewers Checklist Thirty-five critical data points & 5 non-critical data points are
required for part qualification piece sample
Critical and non-critical data points must be taken from the same 35Five parts from a production run must be shipped to NCR for
verification of form, fit, and function dimensions
The same 5 parts will be used to verify both critical and non-critical Supplier must clearly identify which of the 35 parts are being shipped Supplier should make every effort to ship 5 parts that represent both
the low and high ends of the specifications for non-critical dimensions greater than 1.33 for non-critical dimensions
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For products with NCR-developed material specifications and/or an NCR-approved supplier list, the supplier shall procure materials and/or services from suppliers on that list
Performance Test Results The supplier shall perform tests for all parts or product materials when performance or functional requirements are specified by the design record or Control Plan
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Material Results
Revision Level
OK
Not OK
Material Results shall include: The name of the laboratory that conducted the test The type of test that was conducted The number, date, and specification to which the part was tested The actual test results
Signature
Title
Date
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Revision Level
Type of Test
Test description
Parameters Tested
OK
Not OK
Module Test Results shall include: The name of the laboratory that conducted the test The type of test that was conducted A description of the test The parameters tested The actual test results
Signature
Title
Date
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Even though Initial Process Study is coded as an R on the PPAP Submission Level Table, we felt it was important to provide a brief overview during training
R = Supplier shall retain at appropriate locations, including manufacturing and make readily available to the customer representative upon request
S = The supplier shall submit to designated customer product approval activities and retain a copy of records or documentation items at appropriate locations, including manufacturing R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer representative upon request * = The supplier shall retain at appropriate locations, and submit to customer upon request. The customer will identify what is needed for submission base on changes and conditions
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LSL
P rocess D ata LS L 24.5 Target * USL 25.5 S ample M ean 25.1877 S ample N 100 S tD ev (Within) 0.26108 S tD ev (O v erall) 0.266035
What is It?
Objective or Purpose
24.6
O bserv ed P erformance P P M < LS L 0.00 P P M > U S L 110000.00 P P M Total 110000.00 E xp. PPM PPM PPM
24.8
25.0
25.2
25.4
25.6
25.8
C apability H istogr am
UCL=25.5380 _ _ X=25.1877
LSL USL
25.25 25.00
R C har t
UCL=1.284
Sample Range
To evaluate the performance of your process as compared to specification limits. To determine if the production process is likely to produce product that will meet customer requirements
When to Use It
24.5 25.0 25.5 26.0
LCL=0
C apability P lot Within S tD ev 0.26108 Cp 0.64 C pk 0.4 Within O v erall S pecs O v erall S tDev 0.266035 Pp 0.63 P pk 0.39 C pm *
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Step 1
Step 2 Step 3
Step 4
Step 5
Step 6
Step 7
1. Decide on the product or process characteristic to be assessed 2. Validate the specification limits
Step 1
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Step 2
talking to:
Customers, suppliers, controlling agencies
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Step 3
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Step 4
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Step 4
Example:
A die cut machine produces 100 plastic parts per Use subgroups to separate the 2 types of variation in a process: hour. The quality engineer measures 5 randomly selected parts thesubgroup: beginning everyamong hour. Each at Within Theof variation measurements within subgroups; also known as common cause sample of 5 parts is a subgroup.
variation
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Step 5
15
10
10
12
Bimodal Data
Histogram of Mfg Hours
25
Mean StDev N 19.98 1.713 100
14 16 Mfg Hours
18
20
22
The shape of your data is important for determining which type of Capability Analysis applies.
20
15
Frequency
Frequency
15
10
10
16
18
Normal Data
20 Mfg Hours
22
24
-15
15
Skewed Data
30 45 Mfg Hours
60
75
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Step 6
Process is stable and in control Capability is only valid when the process being studied is stable!
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Step 7
Calculate the appropriate statistical metrics in order to determine how the Voice of the Process compares to the Voice of the Customer.
Capability Metrics: PPM, DPMO, Cp, Cpk, Pp, & Ppk ; Sigma Levels (Z Scores)
Specification Limits Specification Limits
Process is capable
If you were driving a truck, and the dotted lines were the construction barriers, what would be happening in each situation?
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The initial process study should be focused on variable, not attribute data
Assembly errors, test failures, and surface defects are examples of attribute data, which is important to understand, but is not covered in this initial study To understand the performance of characteristics monitored by attribute data will require more data collected over time Unless approved by an authorized NCR representative, attribute data are not acceptable for PPAP submission
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Capability Indices
Capability Index
Formula
(USL LSL)
What it shows
Relates short term (within subgroup) standard deviation to tolerance best the current process can do, if centered
Cp
Cpk
estimate potential Relates short term mean & short term (within process capability Min{(USL X), (X LSL)} subgroup) standard deviation to tolerance
3*sshort-term
(USL LSL)
Sometimes called Entitlement, meaning it is the 6*s Cp/Cpk short-term are used to
Only tells you about the nearest spec limit; doesnt tell anything about the other side
PP
Ppk
Pp/Ppk are used to measure actual Relates mean & long term (overall) standard Min{(USL X), (X performance LSL)} process deviation to tolerance
3*slong-term
6*slong-term
Only tells you about the nearest spec limit; doesnt tell anything about the other side
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Acceptance Criteria
Non-Critical
<1.00 1.00-1.33 >1.33
Decision
Cpk must be greater than or equal to 1.67 for critical processes Cpk must be greater than or equal to 1.33 for non-critical processes
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an external laboratory is used, the supplier shall submit the test results on the laboratory letterhead or the normal laboratory report format name of the laboratory that performed the tests, the date(s) of the tests, and the standards used to run the tests shall be identified.
The
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What is It?
Application Date Supplier Code Other
E/C Level
Appearance Evaluation
Supplier Sourcing and Texture Information Pre-Texture Evaluation Correct and Proceed Correct and Resubmit Approved to Texture Customer Representative signature and Date
Objective or Purpose
To demonstrate that the part has met the appearance requirements on the design record
Color Evaluation
Color Suffix Tristimulus Data DL* Da* Db* DE CMC Master Master Material Material Number Date Type Source Red Yel Hue Grn Blu Value Chroma Gloss Color Metallic Part Shipping Brilliance Disposition Suffix
When to Use It
Comments: Supplier Signature Phone No. Date Customer Representative Signature Date
IMPORTANT!
Typically only applies for parts with color, grain, or surface appearance requirements
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Supplier Sourcing & Texture Information Buyer List all first surface tools, graining Source(s), grain type(s), and grainLocation and Manufacturing Gloss masters used to check part
Part Submission Warrant Pre Texture Special Sample First Production Shipment
Drawing Number
Application E/C Level Date Pre-Texture Evaluation To be completed by Supplier SQE Code
Re-Submission Engineering Change
Other
Appearance Evaluation
Supplier Sourcing and Texture Information Pre-Texture Evaluation Correct and Proceed Correct and Resubmit Approved to Texture Customer Representative signature and Date
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Color Evaluation
Color Suffix Tristimulus Data DL* Da* Db* DE CMC Master Master Material Material Number Date Type Source Red Yel Hue Grn Blu Value Chroma Gloss Color Metallic Part Shipping Brilliance Disposition Suffix
Tristimulus Data List numerical (colorimeter) data of submission part as compared to the customerComments: authorized master
Supplier Signature Phone No. Date
Part Disposition Hue, Value, Chroma, Gloss, and To be determined by Metallic Brilliance NCR (approved or Visual assessment by NCR rejected)
Date
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What is It?
Actual samples that reflect the parts documented in the PPAP.
Objective or Purpose
Confirm cosmetic or functional part approval.
When to Use It
Sample parts should be delivered WITH the PPAP submission
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The sample parts provided should be the same parts measured for the dimensional results Default quantity for all submissions is 3 parts unless otherwise requested
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Quantity Serial
Supplier Part
Country
Indication Approval
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PPAP Summary
The Production Part Approval Process is an extensive approval process for new or changed designs or processes It is very formalized, so it inevitably causes some administrative work Later changes to the product or process can be expensive and time-consuming!
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APPENDIX CAPABILITY
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Process Capability
Defective
Variable
Data Type?
Attribute
Defect or Defective
No
Defect
Yes
No
Yes
Rational Sub-groups?
No
No
Yes
Yes
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Capability Normal
Capability - Normal
Capability Non-Normal
Distribution Identification Central Limit Theorem Box Cox Transformation
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Using the data in a Minitab file Capability Example.MTW determine the capability of the PO process in terms of the time is required to process the POs.
Time to Process one individual PO
Yes ???
A
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b.
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P otential (Within) C apability Cp 0.45 C PL 0.48 C PU 0.41 C pk 0.41 C C pk 0.45 O v erall C apability Pp PPL PPU P pk C pm 0.44 0.47 0.41 0.41 *
StDev (Within): Represents short term data. 18 24 StDev (Overall): O bserv ed P erformance E xp. Within P erformance Represents long term data, % < LS L 7.50 % < LS L 7.54 includes shift and%drift % > U S L 10.00 > U S L 10.69 % Total 17.50 % Total 18.23 between subgroups.
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Capability indices: USL Based on short term data. Capability indices: Based on long term data.
Within Ov erall
P otential (Within) C apability Cp 0.45 C PL 0.48 C PU 0.41 C pk 0.41 C C pk 0.45 O v erall C apability Pp PPL PPU P pk C pm 0.44 0.47 0.41 0.41 *
Exp Overall Performance: Based on StDev (Overall) and represents long term process capability.
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Using the data (Time_2) in a Minitab file Capability Example.MTW determine the capability of the PO process in terms of the time that is required to process the POs.
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Are the reasons for non-normality understood? Yes Can the data be described by another distribution? ???
A
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Non-normal
Try Individual Distribution Identification
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3. 4. 5. 6.
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10. Add target value (if applicable). 11. Under Display select 9. Capability Stats 10. Benchmark Z 12. Add Title if desired. 13. Click [OK]. 14. Click [OK].
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Sample Mean
P rocess D ata LS L 20.00000 Target * USL 40.00000 S ample M ean 31.04100 S ample N 200 S hape 1.00817 S cale 6.06360 Threshold 24.99750 O bserv ed P erformance P P M < LS L 0 P P M > U S L 75000 P P M Total 75000
USL
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Using the data (Time_3 and Time 3 sub) in a Minitab file Capability Example.MTW determine the capability of the PO process in terms of the time is required to process the POs.
Average time to process five POs per day Time to process one individual PO
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A
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Non-normal
Try sub-grouping the data
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Important!
The sub-groups have to make logical sense, such as by day, by shift, by machine
5.
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8. 9.
Select [Options] button. Add target value (if applicable). 8. 9. Parts per million or Percents Capability Stats or Benchmark Z
11. Add Title if desired. 12. Click [OK]. 13. Click [OK].
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StDev (Within): Represents short term data StDev (Overall): 15 20 25 Represents long term data, O bserv ed P erformance E xp. Within P erformance includes shift and drift P P M < LS L 85000.00 P P M < LS L 67997.38 between subgroups P P M > U S L 175000.00 P P M > U S L 123688.49
P P M Total 260000.00 P P M Total 191685.87
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Capability indices: USL Based on short term data. Capability indices: Based on long term data.
Within Ov erall
P otential (Within) C apability Cp 0.44 C P L 0.50 C P U 0.39 C pk 0.39 O v erall C apability Pp PPL PPU P pk C pm 0.40 0.45 0.35 0.35 *
Exp Overall: Performance: Based on StDev(Overall) and represents long term process capability.
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Using the data (Time_4) in a Minitab file Capability Example.MTW determine the capability of the PO process in terms of the time is required to process the POs.
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Are the reasons for non-normality understood? Yes Can the data be described by another distribution? No Can the data be sub-grouped? Can data be transformed? ??? No
A
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Non-normal
Try Box-Cox transformation
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Box-Cox Transformation
1. 2. 3. 4. 5. 6. 7. 8. 9. Open the worksheet Capability Example.MTW Choose Stat > Control Charts > BoxCox Transformation Choose [All Observations in one column] from pull down menu Click in Large Box Double click [Time_4] in the column on the left Click in the [Subgroup Size] field enter 1 Select [Options] radio button Select [Optimal Lambda] Enter column for Stored Data
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StDev
50 40 30 20 10 -1 0 1 Lambda 2 3
Transformed Data
Limit
Lambda Values
Caution!
Check transformed data for normality. If the data is not normal then this method cannot be used!
5. Click in the [Subgroup Size] field enter 1 (the data is already sub-grouped) 6. Type 20 in Lower Spec 7. Type 40 in Upper Spec
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P rocess D ata LS L 20.00000 Target * USL 40.00000 S ample M ean 27.73850 S ample N 200 S tD ev (Within) 20.18069 S tD ev (O v erall) 23.20715 A fter Transformation LS L* Target* U S L* S ample M ean* S tD ev (Within)* S tD ev (O v erall)* 1.49272 * 1.63770 1.49973 0.16316 0.17276
transformed data
1.20
O bserv ed P erformance % < LS L 47.00 Transformed % > U S L 23.00 Sample Data % Total 70.00 E xp. Within P erformance % < LS L* 48.29 % > U S L* 19.89 % Total 68.18
1.35
1.50
1.65
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Capability Using Box-Cox Transformation With indices: Lambda = 0.133725 Based on short term data
P rocess D ata LS L 20.00000 Target * USL 40.00000 S ample M ean 27.73850 Exp Within S ample N 200 Based Performance: S tD ev (Within) 20.18069 on (Within) and S tD ev (O vStDev erall) 23.20715
transformed data
LS L*
U S L*
Capability indices: Based on long term data. Exp Overall Performance: Based on StDev (Overall) and represents long term process capability.
Within O v erall P otential (Within) C apability Cp 0.15 C P L 0.01 C P U 0.28 C pk 0.01 C C pk 0.15 O v erall C apability Pp PPL PPU P pk C pm 0.14 0.01 0.27 0.01 *
1.20
O bserv ed P erformance % < LS L 47.00 % > U S L 23.00 % Total 70.00 E xp. Within P erformance % < LS L* 48.29 % > U S L* 19.89 % Total 68.18
1.35
1.50
1.65
1.80
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