Ppap For Neel Metal
Ppap For Neel Metal
Ppap For Neel Metal
MTG. BRACKET 15 LTR AIR TANK PART NO. F1F000914 (ON FVDP VEHICLES)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Part Number
F1F00914 #.0 0
Dated Dated
11/5/2013
Additional Engineering Changes Shown on Drawing Number Checking Aid Number SUPPLIER MANUFACTURING INFORMATION Purchase Order No. Engineering Change Level SUBMISSION INFORMATION
Dimensional
Materials/Function
Appearance
Rudrapur/U.S.N/ U.K./263153
City/District/State/Pin code Note: Application
FVDP VEHICLES
Yes Yes No No
Does this part contain any restricted or reportable substances? Are plastic parts identified with appropriate ISO marking codes?
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) 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 These results meet all drawing and specification requirements: Mold / Cavity / Production Process DECLARATION I 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 Prem Thukral Title Business Partner Phone No. 9760047600 Date FOR CUSTOMER USE ONLY (IF APPLICABLE) Approved Part Functional Approval: Rejected Other Fax No. 250 / 12 hours. I have noted any deviations from this declaration below. material and functional tests YES appearance criteria statistical process package NO (If "NO" - Explanation Required) Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part Processing Parts produced at Additional Location Other - please specify
Blanking & shearing - punching - bending - welding - fastning - final inspection - packing
12/5/2013
Approved Waived
Customer Name
Customer Signature
Date
Blank Dim.
Blank Dim.
Rivet
Standard
10 X5 mm
10 20 30 40 50 60 70 80 100
Chemical Composition Handeling Inadequate Dimensions, Appearance Dimensions,location Dimensions Thick,Appearance Appearance Appearance
Blanking & Shearing Shear Cutter/Automate Punching Bending Welding Fastning & Assembly Final Inspection Dispatch to Customer CNC Turret Punch Press/Automate Bending M/c/Manual MMAW Rivited Inspection Room Dispatch Area
Receipt material Material Movement Component Movement Component Movement Component Movement Component Movement Component Movement Component Movement Standard Packing
PROCESS PFMEA
FMEA NO. : FMEA/MTG. BRACKET/01 PART NAME :MTG. BRACKET- 15 LTR AIR TANK PART NO. : F1F00914 #.0 CORE TEAM : Mr.Pryank, Mr.Ramu Sharma , Mr. Satnam singh DATE (ORIG.) REVISION NO. : : 12/05/2013 00 -REVISION DATE :
PREPARED BY. :Amit Joshi C L A S S POTENTIAL CAUSE(S)/ MECHANISM(S) OF FAILURE O CURRENT PROCESS C CONTROLS PREVENTION C CURRENT PROCESS CONTROLS DETECTION
MTC, DIMENSIONAL AND VISUAL CHECK.
Opern No.
FUNCTIONS
S E V
D E T
R P N
RECOMMENDED ACTION(S)
APPROVED BY : Prem Thukral RESPONSBILITY ACTION RESULTS & TARGET ACTIONS S O D COMPLETION TAKEN DATE
R P N
REQUIREMENTS
10
WRONG MATERIAL USED AT SUPPLIER END. DESIRE LOCATION NOT AVAILABLE SETTING DISTURB
SUPPLIER
20
STORAGE
Material Mixup MATING PART NOT FIT PROPERLY PROBLEM AT CUSTOMER END MATING PART NOT FIT PROPERLY MATING PART NOT FIT PROPERLY MATING PART NOT FIT PROPERLY MATING PART NOT FIT PROPERLY PROBLEM AT CUSTOMER END PROBLEM AT CUSTOMER END IMPROPER STRENGTH IMPROPER STRENGTH
SEPARATE AREA DEFINED FOR EVERY CHECKLIST MATERIAL. LOCK PROVIDED SET UP APP &100% INSP APP &100% INSP APP &100% INSP APP &100% INSP APP &100% INSP APP &100% INSP SET UP APP &100% INSP
48
75
30
SETTING DISTURB
LOCK PROVIDED
75
Improper Location
SETTING DISTURB
56
56
SET TOOL CHANGE 2 FREQUENCY SET TOOL OR DIE 1 CHANGE FREQUENCY 2 LOCK PROVIDED
56
Burr
56
SETTING DISTURB
50
SETTING DISTURB UNSKILLED WELDER AIR/HYDROGEN ENTRAPMENT & IMPROPER FLUX USED POWER/HEAT INPUT TO LOW IMPROPER HOLDING IN FIXTURE
LOCK PROVIDED WEDER TRANING PROVIDED PROPER SHIELDING & FLUX USED
SET UP APP &100% INSP APP &100% INSP APP &100% INSP
50
50
60
WELDING
50
IMPROPER PENITRATION
IMPROPER STRENGTH MATING PART NOT FIT PROPERLY DAMAGE COPONENT REACH TO THE CUSTOMER END.
PROPER APP &100% POWER/HEAT INPUT INSP PROVIDED APP &100% INSP
50
70
IMPROPER FASTNING
50
90
PACKING
2 TRAINING
VISUAL INSPECTION
60
LEGENDS:
S = SEVERITY
Pre-Launch
CP/MTG.BRACKET/01 MTG. BRACKET -15LTR AIR TANK F1F00914 #.0
Production
Core Team :Name Amit Joshi Pryank Ramu Sharma Deptt. Quality Process Process Sign.
: :
Approved By : Methods
Spl. Char. Class Product/process Specification/ Tolerance Evaluation/ Measurement Technique Material Test Certificate Micro Meter
Sample
Control Method
Reaction Plan
Freq. Per Lot Per Lot Raw Material Register Raw Material Register
10
Receiving of Material
All
2mm, 5 mm, 3 mm
20
Storage
Storage Area
All
Racks
Quantity
AS per Challan
100%
Lot
Dimension
Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Standard Sample
Per Hour Per Hour Per Hour Per Hour Per Hour Per Hour Per Hour IIR IIR IIR
30
Dimension
Dimension
Dimension 1 Location
Dia : 5 - 5.1 mm Dia : 8.5 - 8.6 mm Dim : 9 0.1 mm ( From Outer Side )
Dim : 57 0.1 mm ( from center Vernier Caliper line ) CNC Turret Punch Press/Automate
Dimension 2 Location
Dia : 5 0.1 mm Dim : 9.5 0.1 mm (counter sunk height) Dim : 56 0.1 mm(from centre line) Dia : 20 - 21 mm Dim : 15 1 mm outer side ) Dim : 55 1 mm Center Line) ( From (From
Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper
40
Punching
Dimension 3 Location
n=7 n=7
Every 2 hr Every 2 hr
IIR IIR
50 Bending 1
Bending m/c
n=7 n=2
Every 2 hr Every 2 hr
60 Welding
MMAW
Dimension
17 - 0.15 mm
Vernier Caliper
n=7
Every 2 hr
IIR
70
Reviting m/c
Diameter Dimension
11 - 12 mm, 5 mm
n=7 n=7
Every 2 hr Every 2 hr
IIR IIR
80
Final Inspection
Inspection Room
All
Appearance
Visual
n=100%
Every Lot
No Recording
90
Packing
Packaging Area
Quantity
250 Pcs
Every Lot
Pre-Launch
CP/MTG.BRACKET/01 MTG. BRACKET -15LTR AIR TANK F1F00914 #.0
Production
Core Team :Name Amit Joshi Pryank Ramu Sharma Spl. Char. Class Product/process Specification/ Tolerance Evaluation/ Measurement Technique Deptt. Quality Process Process Sign.
: :
Control Method
Reaction Plan
Size
100
Dispatch
Dispatch Area
DATE :
S.N.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DESCRIPTION
2mm, 5 mm, 3 mm
SPECIFICATION
Micro Meter
1
2,5,3 710 25 160 40 140 35 111 5 8.5 9 57 5 9.5
2
2,5,3 711 25 160 40 140 35 111 5 8.5 9 57 5 9.5
3
2,5,3 710 25 161 40 140 36 112 5 8.5 9 57 5 9.5
4
2,5,3 710 26 159 40 141 36 111 5 8.5 9 57 5 9.6
Dim 709 -711 mm Vernier Caliper Dim : 26 - 24 mm Vernier Caliper Dim : 160 1 mm Vernier Caliper Dim : 40 1 mm Dim : 140 141mm Dim : 35 1 mm R : 111 1 mm Dia : 5 - 5.1 mm Vernier Caliper Vernier Caliper Vernier Caliper Standard Sample Vernier Caliper
Dia : 8.5 - 8.6 mm Vernier Caliper Dim : 9 0.1 mm Vernier Caliper Dim : 57 0.1 mm Vernier Caliper Dia : 5 0.1 mm Vernier Caliper
15
Dimension Dimension
Dim : 9.5 0.1 mm Vernier Caliper (counter sunk height) Dim : 112 0.1 mm(from centre Vernier Caliper line) Dia : 20 - 21 mm Vernier Caliper
112 20
112 20
112 21
112 20.5
16
Dim : 15 1 mm Vernier Caliper ( From outer side ) Dim : 55 1 mm (From Center Line) R : 2.5 0.1 mm R : 8 0.1 mm R : 105 0.1 mm 17 - 15 mm 5 x 10 mm
15
15
15
15
Vernier Caliper Standard Sample Standard Sample Standard Sample Vernier Caliper Vernier Caliper
24
Appereance
Free from burr , sharp edges and Visual other Weld Defect
ok
ok
ok
ok
ok
CHECKED BY.
APPROVED BY.
No. Of Appraisers Average 8 218 217 217 217.33 1 217 217 218 217.33 1 217 217 217 217 0 217.22 218 217 217 217.33 1 217 217 218 9 218 217 217 217.3333 XBarA RBarA 1 217 217 218 10
217.3333 0.9
217.33 217.3333 XBarA 1 1 RBarA 217 217 217 217 217 217 217 0 217.22 217 XBarA 0 RBarA Xdbar 217.2222 Rp
217.3333 0.7
= =
1.376 0
Xbardiff = Max Xbar - Min Xbar Rdbar = Average of Rbar D4 = 3.27 For 2 Trials & 2.58 For 3 Trials D3 = 0 for 1 to 7 trials % Total Variation Trials 2 3 App 2 3 K1 % EV 4.56 3.05 K2 % AV 3.65 2.7 = = 100 [ EV / TV ] 217.86 %
Measurement Unit Analysis Repeatablity : Equipment Variation (EV) EV = Rdbar X K1 = 0.533333 X 3.05 0.0061 = Reproducibility : Appraiser Variation (AV) 2 2 AV = (Xbardiff X K2) - (EV / nr) = 0.0005 Repeatablity & Reproducibility (R&R) R&R = (EV2 + AV2 ) = 0.0061 Part Variation (PV) PV =Rp =
= =
100 [ AV / TV ] 17.86 %
Parts 2 3 4 5 6 7 8 9 10
X K3 0.0288
% R&R = 100 [ R&R / TV ] K3 = 218.59 % 3.65 2.7 2.3 % PV = 100 [ PV / TV ] 2.08 = 1028.57 % 1.93 1.82 1.74 No. of distinct catagories (ndc) = 1.41* (PV / R&R) 1.67 = 6.6348 1.62 = 5 Result ACCEPTABLE
Prepared By
Amit Joshi
Approved By
Prem Thukral
Prepared By
Approved By
Anish Bagga
t Certificate
Of
Of
item
Of
item no 1
Of
item no 2
Of item no. 3
PART NAME :MTG. BRACKET- 15 LTR AIR TANK DIMENSION / CHARACTERISTICS MEASURING INSTRUMENT ID NO.
Micro Meter Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Standard Sample Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Standard Sample Standard Sample Standard Sample Vernier Caliper Vernier Caliper Visual Pcs 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM
S.NO.
RANGE / L.C.
0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM 0-25 / 0.01MM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26
Dim 2mm, 5 mm, 3 mm Dim : 709 - 711mm Dim : 26 - 24 mm Dim : 160 1 mm Dim : 40 1 mm Dim : 140 - 141mm Dim : 35 1 mm R : 111 0.1 mm Dia : 5 - 5.1 mm Dia : 8.5 - 8.6 mm Dim : 9 0.1 mm Dim : 57 0.1 mm Dia : 5 0.1 mm Dim : 9.5 0.1 mm (counter sunk height) Dim : 112 0.1 mm(from centre line) Dia : 20 - 21 mm Dim : 15 1 mm Dim : 55 1 mm R : 2.5 0.1 mm R : 8 0.1 mm R : 105 0.1 mm 17 - 0.15 mm 5 x 10mm Free from burr , sharp edges and other Weld Defect 50 Pcs ( From outer side ) (From Center Line)
DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION Visual Pcs
Date: 15/05/2013