Ppap Spacer Tube

CLIENT NAME:
PART NAME:
PART NUMBER:
SL.No REQUIREMENTS ENCLOSED NOT APPLICABLE
AVAILABLE WITH
SUPPLIER
1 DESIGN RECORDS P
2 APPROVED ENGG CHANGE DOCUMENTS X
3 CUSTOMER ENGINEERING APPROVAL X
4 DFMEA X
5 PROCESS FMEA P
6 PROCESS FLOW DIAGRAM P
7 CONTROL PLAN P
8 MSA STUDIES P
9 DIMENSIONAL RESULTS P
10 MATERIAL, PERFORMANE TEST RESULTS P
11 INITIAL PROCESS STUDIES P X
12
QUALIFIED LABORATORY
DOCUMENTATION
P
13 APPEARANCE APPROVAL REPORT X
14 SAMPLE PRODUCTION PART P
15 MASTER SAMPLE P
APPROVED SAMPLE
RETAINED BY KLT
16 CHECKING AIDS P
17 RECORDS OF COMPLIANCE X
18 PART SUBMISSION WARRANT P
ICON INDUSTRIES
PRODUCT PPAP DOCUMENTATION INDEX
KLT AUTOMOTIVE & TUBULAR PRODUCTS LTD.
SPACER TUBE SHOCK-ABSORBER
A 400 311 00 56
PPAP Workbook - Revision history
THE FOLLOWING LEVELS OF DOCUMENTS WERE USED TO PREPARE THIS WORKBOOK.
RELEASE
STATUS
DATE OF REVISION/ IF
APPLICABLE REPLACED
DOCUMENT NUMBER
DOCUMENT DESCRIPTION EDITION
RELEASE
DATE
PAGES MODIFICATIONS
REASON FOR
MODIFICATION
MODIFIED BY
Reference : Production Part Approval Process - AIAG
Manual
Fourth Mar-06
VERSION 1.0 Production Part Approval Process : Formats First Apr-11
VERSION 1.1 19.August.2011 Measurement system analysis Second Aug-11 3
- Gage R&R (Attribute)
- Bias calculation
- Linearity calculation
- Stability calculation
- Introduced
3trials,3approasers w.r.t. MSA
4th edition
- Bias, lineriaty, stability not
available in previous version
SCMQ-PMS team
VERSION 1.1 19.August.2011 Process FMEA Fourth Aug-11 1 - Fourth edition format inclusion
Change in AIAG PFMEA from
3rd to 4th edition
SCMQ-PMS team
VERSION 1.1 19.August.2011 DS/DZ characteristics Aug-11 1 - Newly added New DICV requirement SCMQ-PMS team
April
2011
Revision sheet Page 3 of 37
PPAP WORKBOOK V1.0
Comments:
Date 17-Feb-11
Part Name SPACER TUBE SHOCK-ABSORBER
Part Number A 400 311 00 56
ZGS level (Engineering Change) ZGS : 002
ZGS Change level date (Engineering Change Level Date)
Supplier Name ICON INDUSTRIES
Supplier Code 70946
Street Address TALWADE
City PUNE
State Maharastra
Zip 412114
Phone Number 91-9422365911 / 9225611571
email icon.shubham@gmail.com
Customer Name KLT Automotive & Tubular Products Ltd.
Division Quality Assurance
Application HDT -
Phone Number 91-44-4591 0635
SM email quality.chennai@kltgroup.net
SM Name K.Patchai
Vehicle Model HDT
Applicable Variants 25T,31T,40T & 49T
File Name FILE.XLS
Company Name or logo
DICV
details
The checklists used for PPAP have certain common details repeated in all of them . In order to avoid multiple entry by supplier manager, all such
repetitive details are compiled in column C (Daimler blue). All details entered in coulmn C (Daimler blue) will automatically be updated in the relevant
checklists. It is mandatory for supplier managers to update this workbook for each part.
Supplier
details
Part
details
April
2011
Introduction sheet Page 4 of 37
Part Name : SPACER TUBE SHOCK-ABSORBER HDT Revision Level :
Part Number : A 400 311 00 56 25T,31T,40T & 49T
Supplier Name : ICON INDUSTRIES ZGS : 002
Supplier Code : 70946 Date : 17-Feb-11
Attachment
Approval date
Approver Name
Approver Department
ZGS Level :
Note : Attach all relevant documents
Engineering Change Documents - Element 2
Vehicle Model :
Applicable variants :
Engineering change number
ZGS level (revision number)
April
2011 #DICV/SM/PPAP/CL/ECD02 Page 9 of 37
Part Name : SPACER TUBE SHOCK-ABSORBER HDT Revision Level :
Part Number : A 400 311 00 56 25T,31T,40T & 49T
Supplier Code : 70946 17-Feb-11
Vehicle Model :
Applicable Variants :
ZGS Level:
Date :
Customer Engineering Approval - Element 3
Approver Name
Approver Department
Attachment
Customer engineering approval number
ZGS level (revision number)
Approval date
April
2011
#DICV/SM/PPAP/CL/CEA03 Page 10 of 37
System
Subsystem FMEA Number:
Component Design Responsibility: Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C O Current D
S l c Design e R.
e a c Controls t P. S O D R.
v s u -Prevention e N. e c e P.
s r -Detection c v c t N.
FILE.XLS
Potential Failure Mode and Effects Analysis : DFMEA - Element 4
Item /
Function
Recommended
Action(s)
Responsibility
& Target
Completion
Date
Action Results
Actions
Taken
Potential
Failure
Mode
Potential
Effect(s)
of Failure
Potential
Causes(s)/
Mechanism(s)
of Failure
April
2011
#DICV/SM/PPAP/FR/DFMEA04 Page 11 of 37
Date
Supplier Name
DS
No
DS Charectaristics based on
DICV drawing
Applicable sub part
details of supplier
Deviation
w.r.t base
part (Yes/No)
Control method/measures to secure DS in series
production process
Control Process
Step
Process FMEA
(Yes/No)
Control plan
(Yes/No)
DS1
DS2
DS3
DS4
DS5
DS6
DS7
Note : Use a separate sheet for more than 7 characteristics.
DS Characteristics control method at supplier end & document evidence during series/mass production process (DS form sheet)
Sampling /Inspection Scope Part No
Part Name
Base part / initial release in part family :
August
2011
#DICV/SM/PPAP/FR/DSDZ04 Page 12 of 37
Product Program Issue Date ZGS Level:
Supplier Name Part Name
Supplier Location Part Number
Legend:
Operation Transportation Inspection Delay Storage
Operation or Event Description of Evaluation
Operation or Event and Analysis Methods
10. Reciept of Raw material Verification of Material TC & Incoming Challan
10.A. Inspection of Raw Material Incoming Inspection
10.B. Storage of Accepted Raw material As per Identification & Storage Instructions
20. Machining 1. First Piece Approval
2. Hourly Inspection
30. Finishing & Cleaning 100% Visual Inspection
40. Final Inspection Final Inspection Report / PDIR
50. Packing 1. As per Packing Standard
2. Visual inspection of packing
60. Dispatch As per Challan & Invoice
Process / Inspection Flowchart - Element 5
HDT
April
2011
#DICV/SM/PPAP/FR/PFD05 Page 13 of 37
PART NUMBER: DATE:
PART NAME: ZGS Level:
PREPARED BY:
STEP F
A
B
R
I
C
A
T
I
O
N
M
O
V
E
S
T
O
R
E
I
N
S
P
E
C
T
OPERATION DESCRIPTION I
T
E
M

#
PRODUCT AND PROCESS
CHARACTERISTICS I
T
E
M

#
CONTROL METHODS
10
Reciept of Raw material Quantity as per Challan Supplier Delivery Challan
Inspection of Raw Material 1. Grade : St 52-3 1. Incoming Inspection
10.A 2. Dimensional Specification 2. Supplier Material Test certificate
3. No Damage 3. Supplier PDI
4. No Rust
5. No Dust
10.B
Storage of Accepted Raw material Preservation of Product As per Identification & Storage Instructions
20 Machining 1.Diameter 24 mm 1. First Piece Inspection
2.Inside Diameter 14.25 +0.25 mm 2. Hourly Inspection
3.Length 22.375 -0.5 mm
4.SurfaceFinish Rz 100 (both sides)
5.OD Chamfer 0.5 x 45 (both ends)
6.ID Chamfer 0.5 x 45 (both ends)
7. Perpendicularity 0.5 A
8.Speed
9.Feed
10.Clamping
30 Finishing & Cleaning 1. No Burr 100%Visual Inspection
2. No Rust
3. No Dust
Final Inspection 1. Dimensional Parameters Final Inspection Report / PDI
40 2. No Burr
3. No Rust
4. No Dust
50 Packing 1. Label on the box/ bag 1. As per Packing Standard
2. Quantity written 2. PDIR
3. Manufacturing date 3. Visual Inspection of Packing
4. Part number
5. Customers name
6. PDI report
7. Challan with Quantity
8. Material test report
60 Dispatch 1. No Damage Packing As per Invoice & Challan
2. Qty
SHARAD
ZGS : 002
17-Feb-11
ICON INDUSTRIES
A 400 311 00 56
April
2011
Part Number ZGS Level : Process Responsibility Prepared By
Part Name Engine Series Core Team Date (revised)
Component to Assembly Name Date (original)
Process Flow Diagram Operation Potential Quality Problems Product Characteristics Process Characteristics
operation w/auto inspection rework
w/mult product streams storage partial
transportation inspection operator
decision Delay
10. Reciept of Raw material 1. Short Quantity 1. No Damage Qty as per Challan
2. Reciept of Wrong Part Number 2. No Rust
3. Dust on Parts 3. No Dust
4. Rust on Parts
5. Damaged Parts
10.A. Inspection of Raw Material 1. Raw Material not as per specification 1. Grade : St 52-3
2. Dimensional Variations 2. Dimensional Specification
10.B. Storage of Accepted Raw material 1. Mix up of parts Preservation of Product Storage Instructions
2. Parts Damage
3. Rusting / Dust on parts
20. Machining 1.Diameter oversize / undersize 1.Diameter 24 mm 1.Speed
2.Inside Diameter oversize / undersize 2.Inside Diameter 14.25 +0.25 mm 2.Feed
3.length Variation 3.Length 22.375 -0.5 mm 3.Clamping
4.Surface finish value more than specification 4.SurfaceFinish Rz 100
5.Chamfer oversize / undersize 5.OD Chamfer 0.5 x 45 (both ends)
6.ID Chamfer 0.5 x 45 (both ends)
6.Variation in Perpendicularity 7. Perpendicularity 0.5 A
30. Finishing & Cleaning 1. Burr on Edges 1. No Burr
2. Unclean material 2. No Rust
3. Rusty Components 3. No Dust
40. Final Inspection Skipping of NC commponents 1. Dimensional Specification
2. No Burr
3. No Rust
4. No Dust
50. Packing 1. Less Nos. packed 1. Label on the box/ bag
2. More Nos. packed 2. Quantity
3. Mix up of other part number 3. Manufacturing date
4. Part number
5. Customers name
6. PDI report
7. Challan with Quantity
8. Material test report
60. Dispatch 1. Wrong Qty Dispatch 1. No Damage Packing
2. Wrong Part Number Dispatch 2. Qty
3. Packing Damage
Key Date
R
April
2011
5 NA 2
1. Supplier End Final Inspection
2. Challan approvals
6 60
5 NA 2
1. Supplier PDI
7 70
5 NA 2
1. Designated Locations for
storage with identification tags
7 70
8 2
1. WI for Setting Parameter
2. Tool Monitoring
7 112
8 2
2. Tool Monitoring
7 112
8 2
2. Tool Monitoring
7 112
7 2
2. Tool Monitoring
7 98
7 2
2. Tool Monitoring
7 98
7 2
2. Control Plan
7 98
7 2
2. Tool Monitoring
7 98
6 NA 2
1. Work Instruction for Deburring
& Cleaning
2. Control Plan
6 72
6 NA 2
& Cleaning
2. Control Plan
6 72
6 NA 2
& Cleaning
2. Control Plan
6 72
8 NA 2
1. Gauge calibration system
2. MSA, Training
3. Control Plan
7 112
5 NA 2
Packing Standard display at
packing area 7 70
5 NA 2
packing area
7 70
5 NA 2
Avoid to keep or pack at a time
similar products
7 70
5 NA 2
packing area
7 70
8 NA 2
1. Avoid to keeping or packing at
a time similar products
2. Packing Standard display
6 96
5 NA 2
packing area
7 70
Potential Failure Mode and Effects Analysis : PFMEA- Element 6
1. Raw Material not as
per specification
2. Dimensional
Variation
3. Dust On Parts
4. Rust on Parts
5. Damage Parts
KEY DATE
1. Shortage of Raw material
ICON INDUSTRIES
1. Affect on performance
(Physical & Mechanical
properties)
2. Rejection for next operation
1. Supplier skipped Final
Inspection
SEV
1. Incoming Inspection
1. Incoming inspection
2. Invoice Challan
10.Reciept of Raw
material
10.A Inspection of
Raw Material
POTENTIAL CAUSE(S) /
MECHANISM(S) OF FAILURE
POTENTIAL EFFECT OF
FAILURE
CHECKED PREPARED APPROVED
HDT
PROCESS
FUNCTION /
REQUIREMENTS
CLASS
FMEANUMBER / REV NO :
OCCUR PREVENTION DETECTION RPN
RESPONSIBILITY & TERGET
COMPLETION DATE
ITEM FASTENING PLATE
PROCESS RESPONSIBILITY Sharad, Amit,Balu
MODEL (S) / VEHICLE (S)
POTENTIAL FAILURE
MODE DETECT RPN
FMEADATE ( ORIG )
1. Performance Failure
2. Fitment not OK
3. Damage the assly operator
ACTION RESULTS
ACTION
TAKEN
SEV RECOMMENDED ACTION (S)
1. First Piece Inspection
Storage Inspections
Asthetic & Performance Failure
1. Asthetic & Performance
Failure
2. Sharp Edges
1. Hourly inspection not followed
2. wrong setting done by operator
3. Tool wear
DETECT
Rejection for next operation
1. Supplier not followed
packing standard
2. Supplier skipped Final
Inspection
1. Operator Fails to Clean
2. Skipped the Finishing operation
OCCUR
3. Tool wear
1. Not kept on Identified place
2. Not following storage
instructions
3. Tool wear
1. Fitment Not ok
3. Tool wear
1. Fitment Not ok
1. Fitment Not ok
CORE TEAM
PFMEA
Perpendicularity not as
per specification
Rusty Components
2. Customer Dissatisfaction
100 % Visual inspection
3. Tool wear
3. Tool wear
4. Wrong clamping
Surface Finish Rough
1. Short Quantity
2. Reciept of Wrong
Part Number
1. Dust On Parts
2. Rust on Parts
3. Damage Parts
4. Mixup of parts
Length
undersize/oversize
Chamfer oversize /
undersize
10.B. Storage of
Accepted Raw
materia
20. Machining
ID undersize/oversize
OD undersize/oversize
1. Operator Fails to deburr
More Nos. packed Loss to company
1) Operator not followed packing
standard
2) Operator adds more numbers
to the box
1. PDI
2. Packing Inspection
1. PDI
Skipping of NC
commponents
1. Customer Line stoppage
2. Fitment Problem
1) In adequate acceptance criteria
defined
2) Appraiser variation
3) Semi Skilled Inspectors
1. PDI
2. Customer Feedback
1) Customer dissatisfaction
2) Cust line stoppage
1. Similar Size / Similar parts kept
side by side
1. PDI
standard
2) Operator adds more numbers
to the box
Packing Inspection
Similar Size / Similar parts kept
side by side
Packing Inspection
standard
2) Operator adds Less numbers to
the box
Chamfer missing
1. Fitment Not ok
Packing Damage
2) Dent & Damage on parts
1) Not Packed properly
2) Not Handled box properly
1. Invoice Challan
2. Customer Feed back
Less Nos. packed
30. Finishing &
Cleaning
40. Final Inspection
50. Packing
60. Dispatch
Wrong Part Number
Dispatch
2) Customer line stoppage
Mix up of other part
number
Burr on edges
Wrong Qty Dispatch
1. Asthetic & Performance
Failure
2. Sharp Edges
2. Operation sequence missed by
Operator
Unclean material
2. Customer Dissatisfaction
1. Operator Fails to Clean
August
2011
#DICV/SM/PPAP/FR/PFMEA06 Page 16 of 37
Prototype Pre-Launch Production
Date
Key Contact Phone
MACHINE, CHARACTERISTICS METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
10 Reciept of Raw
Material
1 Grade Grade: St-52.3 Supplier Test
Certificate
100% Each Lot 1. Incoming Inspection
2. supplier Material Test
certificate
Hold the Material &
inform the supplier
10.A Inspection of
Raw Materia
2 No Damage As per challan & As per PO Physical counting
Against challan
100% Each Lot
3. Supplier PDI Reject & inform to
supplier
10.B. Storage of
Accepted Raw
material
3 No Rust As per drawing Incoming Inspection 10 Each Lot
Reject & inform to
supplier
4 No Dust As per drawing Incoming Inspection 100% Each Lot
Reject & inform to
supplier
5 Dimensional Parameters As per Drawing Incoming Inspection 10% Each Lot
Reject & inform to
supplier
20 Machining Lathe Machine 1 Diameter Speed NA 24 mm Digital vernier 3 Per Hour Check the setting and
adjust
Facing Tool 2 Inside Diameter Feed NA 14.25 +0.25 mm Digital vernier 3 Per Hour Check the setting and
adjust
Side Tool 3 Length Clamping / jaw NA 22.375 -0.5 Digital vernier 3 Per Hour Check the setting and
adjust
4 SurfaceFinish NA Rz 100 Surface Tester 2 Every
Lot
Check the setting and
adjust
5 OD Chamfer NA 0.5 x 45 mm (both side) Angle protector 1 Per Hour Check the setting and
adjust
6 ID Chamfer NA 0.5 x 45 mm (both side) Angle protector 1 Per Hour Check the setting and
adjust
7 Perpendicularity NA 0.5 A Surface Plate & Dial
Stand / Right Angle
1 Per Hour Check the setting and
adjust
30 Finishing &
Cleaning
File 1 No Burr Free from Burr or sharp
edge required
Visual 100% Per Lot Hold & Rework the
parts
Cotton Waste 2 No Rust Free from rust on parts Visual 100% Per Lot
Hold & clean the parts
Anti Rust Oil 3 No Dust & Contamnation Free from dust &
contamnation on parts
Visual 100% Per Lot
Hold & clean the parts
40 Final Inspection 1 Dimensional Parameters 1.Diameter 24 mm
2.Inside Diameter 14.25
+0.25 mm
3.Length 22.375 -0.5 mm
4.SurfaceFinish Rz 100
5. OD Chamfer 0.5 x 45
(both ends)
6. ID Chamfer 0.5 x 45
(both ends)
6. Perpendicularity 0.5 A
1. Digital Vernier
2. Mocrometer
3.Surface plate
4.Angle Protector
10% Per Lot
Reject the Parts
2 Burr, Rust, Dust, Sharp
Edges Etc
Free From Burr, Rust,
Dust,Sharp Edges Etc
Visual 100% Per Lot Hold & Rework the
parts
50 Packing 1 Label on the box/ bag As per Packing Standard Packing Inspection 100% Per Lot Repacking
2 Quantity As per Packing Standard Packing Inspection 100% Per Lot Repacking
3 Manufacturing date As per Packing Standard Packing Inspection 100% Per Lot Repacking
4 Part number As per Packing Standard Packing Inspection 100% Per Lot Repacking
5 Customers name As per Packing Standard Packing Inspection 100% Per Lot Repacking
6 PDI report As per Packing Standard Packing Inspection 100% Per Lot Repacking
7 Challan with Quantity As per Packing Standard Packing Inspection 100% Per Lot Repacking
8 Material test report As per Packing Standard Packing Inspection 100% Per Lot Repacking
60 Dispatch 1
2
No Damage packing
Qty
1. As per Packing Standard
2. No packing Damage
Dispatch Note
Visual & Despatch
Register / Challan
100% Per Lot
As per Invoice & Challan Repacking
100%Visual Inspection
Final Inspection Report /
PDI
Packing Inspection
3. Surface Checking from
Outside Lab
Prepared By Approved By Master Copy Controlled Copy
ICON INDUSTRIES
Core Team
Supplier Code
Control Plan - Element 7
Signature Part Number Latest Change Date
Supplier Date (Orig.) Date (Rev.)
April
2011
#DICV/SM/PPAP/FR/CP07 Page 17 of 37
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed
APPRAISER/ PART AVERAGE
TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2. 2
3. 3
4. AVE x
a
=
5. R
r
a
=
6. B 1
7. 2
8. 3
9. AVE x
b
=
10. R
r
b
=
11. C 1
12. 2
13. 3
14. AVE x
c
=
15. R
r
c
=
16. PART X=
AVERAGE
R
p
=
17. (r
a
+ r
b
+ r
c
) / (# OF APPRAISERS=3) = R=
18. x
DIFF
= (Max x - Min x) = x
DIFF
=
19. * UCL
R
= R x D
4
= UCL
R
=
* D
4
=3.27 for 2 trials and 2.58 for 3 trials. UCL
R
represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
April
2011 #DICV/SM/PPAP/FR/MSA08A Page 18 of 37
VARIABLE DATA RESULTS
NUMBER
NAME
Characteristic Gage Type Appraiser C
Measurement Unit Analysis % Total Variation (TV)
Repeatability - Equipment Variation (EV)
EV = R x K
1
Trials K1 % EV = 100 (EV/TV)
= 2 0.8862 =
= 3 0.5908 =
Reproducibility - Appraiser Variation (AV)
AV =
{(x
DIFF
x K
2
)
2
- (EV
2
/nr)}
1/2
% AV = 100 (AV/TV)
= =
= =
Appraisers 2 3
n = parts r = trials K
2
0.7071 0.5231
Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/TV)
GRR = {(EV
2
+ AV
2
)}
1/2
Parts K
3
=
= 2 0.7071 =
= 3 0.5231
Part Variation (PV) 4 0.4467
PV =
R
P
x K
3 5 0.4030 % PV = 100 (PV/TV)
= 6 0.3742 =
= 7 0.3534 =
Total Variation (TV) 8 0.3375
TV =
{(GRR
2
+ PV
2
)}
1/2
9 0.3249 ndc = 1.41(PV/GRR)
= 10 0.3146 =
= =
For information on the theory and constants used in the form see MSA Reference Manual , Fourth edition.
April
2011 #DICV/SM/PPAP/FR/MSA08A Page 19 of 37
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS VARIABLE DATA RESULTS
NUMBER
NAME
Characteristic Specification Gage Type Appraiser C
APPRAISER/ PART AVERAGE
TRIAL # 1 2 3 4 5 6 7 8 9 10
1. A 1
2. 2
3. 3
4. AVE x
a
=
5. R
r
a
=
6. B 1
7. 2
8. 3
9. AVE x
b
=
10. R
r
b
=
11. C 1
12. 2
13. 3
14. AVE x
c
=
15. R
r
c
=
16. PART X=
AVERAGE
R
p
=
17. (r
a
+ r
b
+ r
c
) / (# OF APPRAISERS=3) = R=
18. x
DIFF
= (Max x - Min x) = x
DIFF
=
19. * UCL
R
= R x D
4
= UCL
R
=
* D
4
=3.27 for 2 trials and 2.58 for 3 trials. UCL
R
represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
April
2011
#DICV/SM/PPAP/FR/MSA08B Page 20 of 37
VARIABLE DATA RESULTS
NUMBER
NAME
Characteristic Gage Type Appraiser C
Measurement Unit Analysis % Tolerance (Tol)
Repeatability - Equipment Variation (EV)
EV = R x K
1
Trials K1 % EV = 100 (EV/Tol)
= 2 0.8862 =
= 3 0.5908 =
Reproducibility - Appraiser Variation (AV)
AV =
{(x
DIFF
x K
2
)
2
- (EV
2
/nr)}
1/2
% AV = 100 (AV/Tol)
= =
= =
Appraisers 2 3
n = parts r = trials K
2
0.7071 0.5231
Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/Tol)
GRR = {(EV
2
+ AV
2
)}
1/2
Parts K
3
=
= 2 0.7071 =
= 3 0.5231
Part Variation (PV) 4 0.4467
PV =
R
P
x K
3 5 0.4030 % PV = 100 (PV/Tol)
= 6 0.3742 =
= 7 0.3534 =
Tolerance (Tol) 8 0.3375
Tol = Upper - Lower / 6 9 0.3249 ndc = 1.41(PV/GRR)
= ( - ) / 6 10 0.3146 =
= =
For information on the theory and constants used in the form see MSA Reference Manual , Fourth edition.
April
2011
#DICV/SM/PPAP/FR/MSA08B Page 21 of 37
PLANT DEPT. OPERATION DATE CONTROL LIMITS CALCULATED ENGINEERING SPECIFICATION PART NO.
MACHINE NO. DATES OF STUDY CHARACTERISTIC SAMPLE SIZE FREQUENCY PART NAME
X = AVERAGES (X BAR CHART)
S = Standard Deviations (S CHART)
AVERAGE
Sigma
LCL LINE
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
DATE/TIME
1
2
3
4
5
SUM
X
SUM
NUM
S Sigma
** = POINT OUT OF CONTROL
D
A
T
A
UCL = LCL =
UCL = LCL =
17-Feb-11
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
April
2011
#DICV/SM/PPAP/FR/MSA08C Page 22 of 37
PLANT DEPT. OPERATION DATE CONTROL LIMITS CALCULATED ENGINEERING SPECIFICATION PART NO.
MACHINE NO. DATES OF STUDY CHARACTERISTIC SAMPLE SIZE FREQUENCY PART NAME
X = AVERAGES (X BAR CHART)
R = RANGES (R CHART)
AVERAGE
Range
LCL LINE
NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
DATE/TIME
1
2
3
4
5
SUM
X AVG
R Range
** = POINT OUT OF CONTROL
17-Feb-11
D
A
T
A
UCL = LCL =
UCL = LCL =
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
April
2011
#DICV/SM/PPAP/FR/MSA08D Page 23 of 37
SPACER TUBE SHOCK-ABSORBER Vehicle Model : HDT
A 400 311 00 56 Applicable Variants : 25T,31T,40T & 49T
ZGS Level : ZGS : 002
Date : 17-Feb-11
Note : Use ok or not ok w.r.t. status in the fields Revision Level :
Tiral 1 Tiral 2 Tiral 3 Tiral 1 Tiral 2 Tiral 3 Tiral 1 Tiral 2 Tiral 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20 20 20 20 20 20 20 20 20
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
20 20 20 20 20 20 20 20 20
100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%
0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Miss Rate
<=2%
<=5%
>5%
100.00%
0.00%
0.00%
Date Date
100.00%
False Alarm
Supplier Code :
GAGE R&R REPORT SHORT FORM ATTRIBUTE RESULTS
Appraiser 1 Appraiser 2
Part Name :
Part Number :
Supplier Name :
Appraiser 3
Sl.No. Master Status
100.00% 100.00%
Miss Rate %
0.00% 0.00% 0.00%
Miss Rate
Total
Total ok
Total Not ok
Effectivenss %
Effectiveness
Result
0.00% 0.00%
Acceptance Criteria
Decision Measurement System Effectiveness False Alarm Rate
Unacceptable for the appraiser -
needs improvement
<80% >10%
False Alarm %
0.00%
Conducted By
Effectivenss %
Miss Rate %
False Alarm %
Accepted
Acceptable for the appraiser >=90% <=5%
Marginally acceptable for the
appraiser - May need improvement
>=80% <=10%
August
2011
#DICV/SM/PPAP/FR/MSA08E Page 24 of 37
Part Name : SPACER TUBE SHOCK-ABSORBER HDT
Part Number : 25T,31T,40T & 49T
Supplier Code : 70946 17-Feb-11
Number of Trials: 12 5
1 2 3 4 5
TRIAL READINGS
1
2
3
4
5
6
7
8
9
10
11
12
Average #DIV/0!
1 2 3 4 5
Reference Value
TRIAL bias array
1
2
3
4
5
6
7
8
9
10
11
12
Average #DIV/0!
Date :
A 400 311 00 56
Reference Value
Number of References :
LINEARITY DATA SHEET
Vehicle Model :
ZGS Level :
August
2011
#DICV/SM/PPAP/FR/MSA08F Page 25 of 37
HDT
25T,31T,40T & 49T
ZGS Level : ZGS : 002
Date :
Revision Level :
DATE:
CHARACT:
S.No
1
2
3
4
5
6
7
8
9
10
(Tolerance)
0.000
#DIV/0!
#DIV/0!
Remarks (if any):
Gage engineer:
Disposition:
Checked By:
Bias ( Observed Average Measurment - Referance value =
Percentage of Tolerance for bias (Bias/Tolerance) =
Result: % of Tolerance Used =
NOTE: If Tolearance used is equal or less than 10% then the gage is OK. Enclose this form along with R &R sheet.
Process variation =
Referance Master Value =
0.000 Average of 10 Readings =
Gage Reading
TOLERANCE: DESCRIPTION :
BIAS STUDY ANALYSIS
Part Name :
Part Number :
Supplier Name :
SPACER TUBE SHOCK-ABSORBER Vehicle Model :
Supplier Code :
GAGE:
ID NO:
70946
MASTER READING:
RANGE:
August
2011
#DICV/SM/PPAP/FR/MSA08G Page 26 of 37
INSPECTION FACILITY:
TITLE DATE
Revision Level :002
SUPPLIER NAME :
SUPPLIER CODE:
PART NUMBER:
PART NAME:
ITEM
DIMENSION /
SPECIFICATION
SPECIFICATION / LIMITS
TEST
DATE
14.25 +0.25 mm
OK
NOT
OK
QTY.
TESTED
ORGANIZATION MEASUREMENT
RESULTS (DATA)
24 mm 1 Diameter
2 Inside Diameter
SurfaceFinish
0.5 x 45 mm (both side)
3 Length 22.375 -0.5
5 Chamfer
Rz 100 4
6 Perpendicularity 0.5 A
SIGNATURE
Blanket statements of conformance are unacceptable for any test results.
Dimensional Test Results - Element 9
April
2011 #DICV/SM/PPAP/FR/D09 Page 27 of 37
MATERIAL SUPPLIER:
*CUSTOMER SPECIFIED SUPPLIER CODE:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:
TITLE DATE
QTY.
TESTED
SUPPLIER TEST RESULTS (DATA) OK
Revision Level :
SUPPLIER NAME :
SUPPLIER CODE:
PART NUMBER:
PART NAME:
Material Test Results - Element 10
NOT
OK
SPECIFICATION /
LIMITS
TEST
DATE
MATERIAL SPEC. NO. / REV / DATE
SIGNATURE
April
2011
#DICV/SM/PPAP/FR/MP10A Page 28 of 37
TITLE DATE
70946
PART NUMBER:
PART NAME:
Performance Test Results - Element 10
*CUSTOMER SPECIFIED SUPPLIER CODE:
SUPPLIER TEST RESULTS (DATA)/
TEST CONDITIONS
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
OK
NOT
OK
TEST SPECIFICATION / REV / DATE
SPECIFICATION /
LIMITS
TEST
DATE
QTY.
TESTED
Revision Level :
A 400 311 00 56
NAME of LABORATORY:
SUPPLIER NAME:
SUPPLIER CODE:
SIGNATURE
April
2011
#DICV/SM/PPAP/FR/MP10B Page 29 of 37
Date :
USL: LSL:
Gage R&R results for this characteristic
1 51 101 151 201 251 Target 0.0000
2 52 102 152 202 252 Skewness #DIV/0!
3 53 103 153 203 253 Kurtosis #DIV/0!
4 54 104 154 204 254 UCL
Xbar
#DIV/0!
5 55 105 155 205 255 LCL
Xbar
#DIV/0!
6 56 106 156 206 256 Xbar #DIV/0!
7 57 107 157 207 257 D
2
#N/A
8 58 108 158 208 258 Max 0.0000
9 59 109 159 209 259 Min 0.0000
10 60 110 160 210 260 Rbar #N/A
11 61 111 161 211 261 Rbar / D
2
#N/A
12 62 112 162 212 262 UCL
R
#N/A
13 63 113 163 213 263 LCL
R
#N/A
14 64 114 164 214 264 Sigma #DIV/0!
15 65 115 165 215 265 Cp #N/A
16 66 116 166 216 266 Cpu #DIV/0!
17 67 117 167 217 267 Cpl #DIV/0!
18 68 118 168 218 268 Cpk #DIV/0!
19 69 119 169 219 269 Pp #DIV/0!
20 70 120 170 220 270 Ppu #DIV/0!
21 71 121 171 221 271 Ppl #DIV/0!
22 72 122 172 222 272 Ppk #DIV/0!
23 73 123 173 223 273
24 74 124 174 224 274
25 75 125 175 225 275
26 76 126 176 226 276
27 77 127 177 227 277
28 78 128 178 228 278
29 79 129 179 229 279
30 80 130 180 230 280
31 81 131 181 231 281
32 82 132 182 232 282
33 83 133 183 233 283
34 84 134 184 234 284
35 85 135 185 235 285
36 86 136 186 236 286
37 87 137 187 237 287
38 88 138 188 238 288
39 89 139 189 239 289
40 90 140 190 240 290
41 91 141 191 241 291
42 92 142 192 242 292
43 93 143 193 243 293
44 94 144 194 244 294
45 95 145 195 245 295
46 96 146 196 246 296
47 97 147 197 247 297
48 98 148 198 248 298
49 99 149 199 249 299
50 100 150 200 250 300
Statistics Data
Characteristic:
Subgroup size: Nominal:
For 1-sided distributions enter 1 for only USL and 2 for only LSL
April
2011
#DICV/SM/PPAP/FR/IPS11 Page 30 of 37
Part Name : Vehicle Model : HDT
Part Number : Applicable Variants : 25T,31T,40T & 49T
Supplier Name : ZGS Level : ZGS : 002
Supplier Code : Date : 17-Feb-11
Revision Level :
#REF!
Qualified Laboratory Documentation - Element 12
#REF!
National Accreditation Board for Testing and calibaration Laboratories
UI/11-12/L/7606-001/78093
UNIVERSAL INSTRUMENTS
Certification Provider :
Certification Number :
Your Company Name as it appears on the certification and scope:
April
2011 #DICV/SM/PPAP/CL/QLD12 Page 31 of 37
REASON FOR PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION
SUBMISSION PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
PRE-TEXTURE REPRESENTATIVE
EVALUATION SIGNATURE AND DATE
This is document is not necessary for this part as it is under chassis part.
COLOR EVALUATION
COLOR
COLOR TRISTIMULUS DATA MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS BRILLIANCESHIPPING PART
SUFFIX DL* Da* Db* DE* CMC NUMBER DATE TYPE SOURCE RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW SUFFIX DISPOSITION
COMMENTS
ORGANIZATION PHONE NO. DATE AUTHORIZED CUSTOMER DATE
SIGNATURE REPRESENTATIVE SIGNATURE
APPEARANCE APPROVAL REPORT - Element 13
METALLIC
CORRECT AND
PROCEED
CORRECT AND
PROCEED
APPROVED TO
ETCH/TOOL/EDM
PART
A 400 311 00 56 25T,31T,40T & 49T
NUMBER
DRAWING
NUMBER
Validity period
NAME LOCATION
APPLICATION
(VEHICLES)
OTHER
ORGANIZATION SOURCING AND TEXTURE INFORMATION
E/C LEVEL DATE
ORGANIZATION MANUFACTURING
Sholingher
SUPPLIER CODE
PART
NAME
BUYER
CODE
April
2011 #DICV/SM/PPAP/FR/AAR13 Page 32 of 37
Part Name : SPACER TUBE SHOCK-ABSORBER Vehicle Model :
Part Number : A 400 311 00 56 Applicable Variants :
Supplier Name : Quantity (nos):
Supplier Code : ZGS Level : ZGS : 002
Revision Level : Date :
PPAPs that require Sample product will be hand delivered or mailed to DICV
The address is:
Do not send in PPAP with the first shipment of parts.
PPAP must be approved before the first Production shipment.
HDT
25T,31T,40T & 49T
Sample Product - Element 14
17-Feb-11
April
2011 #DICV/PPAP/SM/FR/SP14 Page 33 of 37
Part Number : SPACER TUBE SHOCK-ABSORBER Vehicle Model :
Part Name : Applicable Variants :
Revision Level :
Production Date :
Storage location :
Master Sample - Element 15
HDT
25T,31T,40T & 49T
April
2011 #DICV/SM/PPAP/CL/MS15 Page 34 of 37
Part Number : SPACER TUBE SHOCK-ABSORBER Vehicle Model :
Part Name : A 400 311 00 56 Applicable Variants :
Checking aid number Description of checking aid Qty of equipment Equipment capacity Established place
Compliance with latest engineering
change: Y/N
Date of last calibration
9123135 Digitial Vernier Caliper 1 0 - 300 YURI Y 2/4/2012
47017116 Micrometer 1 25 - 50 MITUTOYO Y 2/4/2012
R1-7mm Radius Gauge 1 R1 - R20 WEST GERMANY Y -----
G012732 Lever Dail Gauge 1 0 - 80 YURI Y 2/4/2012
Revision Level :
Prepared By :
Checking Aids - Element 16
HDT
25T,31T,40T & 49T
April
2011
#DICV/SM/PPAP/FR/CA16 Page 35 of 37
Part Number : SPACER TUBE SHOCK-ABSORBER Vehicle Model : HDT
Part Name : Applicable Variants : 25T,31T,40T & 49T
S.No. Customer specific requirement Remarks
Revision Level :
Prepared By :
Records of compliance - Element 17
Description
April
2011
#DICV/SM/PPAP/CL/RoC17 Page 36 of 37
ICON INDUSTRIES
Truck Industry
Part Name Rev.
If applicable
Tool PO Number 3 Dated
Additional Engineering Changes Dated
Shown on Drawing Number Weight (kg)
Checking Aid Number Dated
ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION
Quality Assurance
Organization Name and Code Customer Name/Division
TALWADE K.Patchai quality.chennai@kltgroup.net
Street Address Customer Contact Customer email
PUNE Maharastra
City State Zip Application
91-9422365911 / 9225611571 icon.shubham@gmail.com
Supplier contact Supplier email
Note: Does this part contain any restricted or reportable substances?
Are plastic parts identified with appropriate ISO marking codes?
REASON FOR SUBMISSION
Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or Additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling inactive > than 1 year Other - please specify
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
(check)
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer
drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular
production process. I also certify that documented evidence of such compliance is on file and available for review.
EXPLANATION/COMMENTS:
List Molds / Cavities / Production Processes NIL
Organization Authorized Signature Date
Print Name
Title E-Mail icon.shubham@gmail.com
FOR CUSTOMER USE ONLY
PPAP Warrant Disposition:
Comment:
Customer Signature Date
Print Name
Part Submission Warrant - Element 18
25T,31T,40T & 49T
ZGS : 002 SPACER TUBE SHOCK-ABSORBER A 400 311 00 56
Engineering Change Level
Customer Part Number
Purchase Order No.
ZGS Level (Engineering Drawing Change) -------
412114
-------
2/17/2011
Fax No. Phone No. 91-44-26526527
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Approved Rejected
Interim Approval
Yes No
Yes No N/A
April
2011
#DICV/SM/PPAP/FR/PSW18 Page 37 of 37

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