Professional Documents
Culture Documents
PPAP
Customer Name: Part Name: Part Number: Rev. Level: Product Program:
PSO Submission Date:
Customer Name:
PPAP
Rev. Level:
Product Program:
Daimler Chrysler
Part Name Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing No. Checking Aid No. SUPPLIER MANUFACTURING INFORMATION 0
Supplier Name & Supplier Code
0
0
Street Address
City
State
Note:
Does this part contain any restricted or reportable substances. Are plastic parts identified with appropriate ISO marking codes
Yes Yes
No No
REASON FOR SUBMISSION Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part Processing Parts Produced at Additional Location Other - please specify
REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report ) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests Yes appearance criteria No statistical process package
These results meet all drawing and specification requirements: Mold / Cavity / Production Process DECLARATION
I hereby 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 EXPLANATION/COMMENTS: Print Name: Supplier Authorized Signature FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition: Approved Other Customer Name
July 1999
Title:
Phone No:
Rejected
Approved Waived
Customer Signature
The original copy of this document shall remain at the suppliers location while the part is active (see Glossary).
Date
Optional: customer tracking number: # _______________
CFG-1001
Daimler Chrysler
GM
Daimler Chrysler
SUPPLIER
0
NAME OF INSPECTION FACILITY PART NAME
0 0
NOT
ITEM
DIMENSION / SPECIFICATION
OK
OK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
MAY 1995 CFG-1003 SIGNATURE TITLE DATE
Daimler Chrysler
GM
Daimler Chrysler
1 of 4
SUPPLIER
0
NAME OF INSPECTION FACILITY PART NAME
0 0
NOT
ITEM
DIMENSION / SPECIFICATION
OK
OK
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
MAY 1995 CFG-1003 SIGNATURE TITLE DATE
Daimler Chrysler
GM
Daimler Chrysler
2 of 4
SUPPLIER
0
NAME OF INSPECTION FACILITY PART NAME
0 0
NOT
ITEM
DIMENSION / SPECIFICATION
OK
OK
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
MAY 1995 CFG-1003 SIGNATURE TITLE DATE
Daimler Chrysler
GM
3 of 4
SUPPLIER
0
NAME OF INSPECTION FACILITY PART NAME
0 0
NOT
ITEM
DIMENSION / SPECIFICATION
OK
OK
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
MAY 1995 CFG-1003 SIGNATURE TITLE DATE
Daimler Chrysler
GM
SUPPLIER
0
NAME OF LABORATORY PART NAME
0 0
TYPE OF TEST MATERIAL SPEC. NO. / DATE / SPECIFICATION SUPPLIER TEST RESULTS OK
NOT OK
MAY 1995
CFG-1004
SIGNATURE
TITLE
DATE
QUALITY MGR.
t l
Operation Move Store Step
n
Inspect Operation Description
10
n l t t t t n t l l
Incoming Inspection Store Material Move To Press Load on Uncioler Straighten Oil Form Inspect Pack Move to Shipping Store in Shipping Ship
20
30
40
50
60
70
80
90
100
110
120
OPERATOR KEY TD MH ST PT TRUCK DRIVER MATERIAL HANDLER / HI-LO STOCK / STORAGE PROCESS / PRESS TECHNICIAN MO AO RC QA MACHINE / PRESS OPERATOR ASSEMBLY OPERATOR RECEIVING CLERK QUALITY INSPECTOR
Flow4/16/2013
Page 10 of 25
1/4/2005
PART NAME:
S T E P Process Function Potential Failure Mode Potential Effect(s) of Failure S E V C L A S S Potential Cause(s)/ Mechanism(s) of Failure Wrong Material Shipped to ATS Wrong Material Shipped to ATS Wrong Material Shipped to ATS Material Clad on Wrong Side Not Set Correctly Oiler not working/ empty Oiler not working/ empty Oiler not working/ empty Oiler set too high Incorrect Progression Die shut Ht. set incorrectly Die/Worn Broken Incorrect label installed Incorrect Date samped on Container
MODEL VEHICLE:
O C C U R 1 Current Process Controls D E T E C T 1 Action Results R P N Recommended Action(s) Responsibility & Target Completion Date
Prevention
Actions Taken
S E V
O C C
D E T
R P N
10
Non Conforming Product Braze Problems at Behr Non Conforming Product Braze Problems at Behr Die Feed Problems Leaks on Assembly Non conforming Product- Dimensional Non conforming Product- Dimensional Braze Problems at Behr Incorrect Part Width/ Collar Ht. Incorrect Collar Ht and Part Flatness Non conforming Product- Dimensional No Build at Behr Braze Problems at Behr
8 4
1 1
40
1 1
8 4
8 2 5 3 3 6 6 6 6 8 8
1 2 2 4 4 2 2 2 2 3 3 Die PM System Visual inspection Die problems Visual inspection Visual inspection Part Layout Part Layout Part Layout/
10 2 8 1 8 8 2 2 2 8 8
80 8 80 12 96 96 24 24 24 192 192
50 60
Straighten Oil
Material not Straight into die Crakcing/ Thinning of material Parts stick in die Burrs on part Oily Parts
70
Form
90
Pack
KB Stamping
FMEA 11/1/04
Page 11 of 25
MODEL VEHICLE:
O C C U R 1 Current Process Controls D E T E C T 1 Action Results R P N Recommended Action(s) Responsibility & Target Completion Date
Prevention
Actions Taken
S E V
O C C
D E T
R P N
10
Incoming Inspection
KB Stamping
FMEA 11/1/04
Page 12 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918
SUPPLIER LOCATION: SUPPLIER PHONE: SUPPLIER CODE: FIRST ISSUED:
REVISED: SUPERCEDES:
KB STAMPINGS REP. PLANT MGR.: _____________________ DATE: _____________ MFG. ENG.: _______________________ Q.A. MGR.: _______________________ DATE: _____________ DATE: _____________
CUSTOMER REP. (IF APPLICABLE) Q.A. REP.: ___________________________ ENG. REP.: __________________________ MGMT. REP.: _________________________
Part Name
Part/ Process Number Process Name/ Operation Description Machine, Device, Jig, Dies For Mfg. Characteristics
Model Vehicle
Special Char. Class Product/Process Specification/ Tolerance
KB NUMBER:
Methods Evaluation Measurement Technique Sample Control Method Size Freq. Reaction Plan
No.
Product
Process
Rec Insp
KB Stamping
Page 13 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Part/ Process Number Process Name/ Operation Description Machine, Device, Jig, Dies For Mfg. Characteristics Special Char. Class Product/Process Specification/ Tolerance Evaluation Measurement Technique
Model Vehicle
KB NUMBER:
Methods Sample Control Method Size Freq. Reaction Plan
No.
Product
Process
10
20
30
KB Stamping
Page 14 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Part/ Process Number Process Name/ Operation Description Machine, Device, Jig, Dies For Mfg. Characteristics Special Char. Class Product/Process Specification/ Tolerance Evaluation Measurement Technique
Model Vehicle
KB NUMBER:
Methods Sample Control Method Size Freq. Reaction Plan
No.
Product
Process
KB Stamping
Page 15 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918
SSUED:
D:
CEDES:
___________
___________
___________
ACTUAL MEASUREMENT
KB Stamping
Page 16 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918
ACTUAL MEASUREMENT
KB Stamping
Page 17 of 25
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918
ACTUAL MEASUREMENT
KB Stamping
Page 18 of 25
Check 1st piece at set-up or start of day and record data. Check 1 part at the start of each coil & 1 part per bin Check Last piece from Production Run, Record Data, Attach last & 1st piece part to fixture Shut down and notify Management of any non conformance Print Rev.: Rev Date: Customer: 0 0 Part Number: Part Name Lot No.: 0 0 Print Specification & Characteristic Sample No. 1 Sample No. 2 Sample No. 3
0 Date:
Sample No. 4
Sample No. 5
KB Stamping
Page 19 of 25
OPERATION INSTRUCTIONS
PART NAME: PART NUMBER: KB JOB NUMBER:
0 0 0
OPERATION(S):
10 Progressive Complete
DATE: DATE:
WORK STATION
OPERATION METHOD
OPERATOR
1) VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE.
PACKAGING INSTRUCTIONS
2) WHEN LOADING MATERIAL INTO DIE, ASSURE THAT IT IS ALIGNED "PARALLEL" TO THE DIE. 3) WHEN THE MATERIAL IS COMPLETELY LOADED, PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT.
BOX
4) WHEN FIRST PIECE IS APPROVED, RUN PRESS IN FULL AUTOMATIC MODE. 5) MONITOR SCRAP REMOVAL SO THAT IT DOESN'T AFFECT DIE. Place packaging picture here
GAGE TABLE
FINISH GOODS SKID
6) WHEN THE CONTAINER IS FULLACCORDING TO PACKAGING INSTRUCTIONS. 7) APPLY COMPLETED PRODUCT INVENTORY LABEL TO SKID.
QUALITY CRITERIA
GAGE INSTRUCTIONS
7) USE FEELER GAGES TO VERIFY PROPER FORM / FORM LOCATION AS SHOWN ON FIXTURE.
5.
1) PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 2) PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 3) PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 4) CLAMP PART ONTO FIXTURE 5) INSERT 11.80MM STAB PIN INTO CENTER HOLE TO VERIFY POSITION 6) REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10 STAB PIN INTO EACH SLOT TO VERIFY POSITION FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS. RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.
7.
8.
6.
Page 20 of 25
0 0 0
DATE: DATE:
SUBJECT PRESS SIZE STOCK (MATERIAL) SIZE COUNTER BALANCE PRESSURE SHUT HEIGHT FEED ROLLER PRESSURE MATERIAL FEED DISTANCE MATERIAL FEED RATE STRAIGHTENING PRESSURE PILOT RELEASE PRESSURE STROKES PER MINUTE OIL (LUBRICANT) AIR HOOK-UP SENSOR HOOK-UP DIE PROTECTION SHORT FEED PART EJECT CAM SWITCH FEED ADVANCE PILOT RELEASE ON
REQUIREMENT
ON
OFF
TONNAGE REFERENCE DIE LOCATION TONNAGE LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR TOTAL TONNAGE SHAKER REFERENCE SIZE LOCATION
TYPE
Page 21 of 25
Item Description 0-1" Mic - Material Thickness Verification Tape - Material Width Verification
No. 1 2 3 4
Description/Rationale
Specification/Tolerance Class. -
Illustration/Pictorial
Page 23 of 25
Date:
Cycle Frequency
Punch/Bull Ring Mounting Wear Plates Storage Cushions Balance Blocks Information Tags Guidance Weight Nitro Pressure Danger Guide Pins Guide Bushings Lifters Cylinders Prox. Switches Cords Boxes Surface Wear Cavity/Pad Punch Post Plate type Pin type Punch Rubbing Nitro Air Internal Pad Gauging Wear Plates Pins & Bushings Rail Gauge Solid Gauge Bottom Blocks
C o m p l e t e
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x
x Check for Legibility x Check for Legibility x Check for Legibility x Check for wear, replace x Check for wear, replace
x x x x x x x x x x x
x x x x x x x x x x x
x x x x x x x x
x x x x x x x x
x Check for leaks x Check for leaks x Check x Check x Check x Check for surface damage x One or x the other
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x Check for damage x Check for damage x Check for damage x Check Nitro Log and/or replace x Replace
x x x x x x x x x x x x x x x x x x x x
x Return to original sizes x Replace bushings/check pins x Check for tight/position/damage x Check for tight/position/damage x Check for tight/position/damage
"X"= Done. 0 = no action needed. NA = not in this die. Legend for complete column
Comments:
Instructions: 1) Check punch and resurface as needed 2) Check upper and lower Steels for wear. Repair as needed. 3) Check beads and gutters for wear. Repair as needed. 4) Check nitro cylinders for leaks. Replace as needed 5) Check lifter system for damage. Repair as needed 6) Check heel and wear plates for proper clearance and wear. Tighten/replace as needed. 7) Check risers and punch mounting plates for loose and missing screws. Tighten/replace as needed. 8) Clean disassembled die. Lubricate where necessary. 9) Check and re-size / re-shim equalizer blocks. 10) Check bolster plate mounting screws. Tighten/replace as needed.
Approval:
Date:
Concurrence:
Date:
Date Revised:
Date Issued: