Apqp Forms

Our Name: Customer Name: Part Name: Part Number: Rev. Level: Rev.
Date: Product Program: Key Production Date:

LAST UPDATE
PPAP
Customer Name: Part Name: Part Number: Rev. Level: Product Program:
PSO Submission Date:
Customer Name:
PPAP
Part Name: Part Number:
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
Part Submission Warrant

0 Yes No Engineering Drawing Change Level Part Number 0 Dated Dated 0 Purchase Order No. Engineering Change Level SUBMISSION INFORMATION Dimensional Supplier Code Customer Name/Division 0 Materials/Functional Appearance Dated Weight (kg) 0
0
0
Street Address
Buyer/Buyer Code MI Application

Zip
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
(if "No" - Explanation Required)
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:
/ 8 hours. I have noted any deviations from this declaration below.
Phone No:
Fax No. Date
Rejected
Part Functional Approval:
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
Production Part Approval ___ Dimensional Results

Page 1 of 4
PART NUMBER
Daimler Chrysler
SUPPLIER
0
NAME OF INSPECTION FACILITY PART NAME
0 0
NOT
ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
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

Page 2 of 4
PART NUMBER
Daimler Chrysler
1 of 4
SUPPLIER
0
0 0
NOT
ITEM
OK
OK
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Daimler Chrysler
GM

Page 3 of 4
PART NUMBER
Daimler Chrysler
2 of 4
SUPPLIER
0
0 0
NOT
ITEM
OK
OK
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Daimler Chrysler
GM

Page 4 of 4
PART NUMBER
3 of 4
SUPPLIER
0
0 0
NOT
ITEM
OK
OK
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
Daimler Chrysler
GM
Production Part Approval ___ Material Test Results

Page 1 of 1 Pages
PART NUMBER
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.
PROCESS FLOW DIAGRAM PART NUMBER: PART NAME: CUSTOMER: E.C.L.:

0 0 0 0
MFG. ENG.: QUAL. ENG.: PLANT MGR.:
t l
Operation Move Store Step
n
Inspect Operation Description
REV. DATE: 11/18/04

Tool / Gage / Fixture / Location / Operator Key Product / Process Characteristics
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
FAILURE MODES EFFECT ANALYSIS
PART NAME AND NUMBER: Rev Level/Date CORE TEAM MEMBERS:
PROCESS RESPONSIBILITY: KEY PRODUCTION DATE: MODEL YEAR(S) / VEHICLE(S):
FMEA DATE (ORIG.): FMEA DATE (REV.): PREPARED BY:
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
Detection Check at receiving
Actions Taken
S E V
O C C
D E T
R P N
10
Incoming Inspection Load Coil on Uncoiler
Incorrect material Dimensional Incorrect alloy
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
Incorrect material Dimensional Clad on Wrong Side
Check Material Certification Check at Press
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
Progression set incorrectly Die Shut Ht. Incorrect Die Worn/Broken
90
Pack
Wrong Part # on Container Wrong "Born on Date"
KB Stamping
FMEA 11/1/04
Page 11 of 25
FAILURE MODES EFFECT ANALYSIS 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
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
Detection Check at receiving
Actions Taken
S E V
O C C
D E T
R P N
10
Incoming Inspection
Incorrect material Dimensional
Non Conforming Product
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:
PROCESS CONTROL PLAN
REVISED: SUPERCEDES:
PART NUMBER/E.C.L.: / PART NAME: 0
PROTOTYPE PRE-LAUNCH PRODUCTION
KB STAMPINGS REP. PLANT MGR.: _____________________ DATE: _____________ MFG. ENG.: _______________________ Q.A. MGR.: _______________________ DATE: _____________ DATE: _____________
CUSTOMER REP. (IF APPLICABLE) Q.A. REP.: ___________________________ ENG. REP.: __________________________ MGMT. REP.: _________________________
DATE: _____________ DATE: _____________ DATE: _____________
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
Production Control Plan 11/1/04
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
SSUED:
D:
CEDES:
___________
___________
___________
ACTUAL MEASUREMENT
KB Stamping
Page 16 of 25
ACTUAL MEASUREMENT
KB Stamping
Page 17 of 25
ACTUAL MEASUREMENT
KB Stamping
Page 18 of 25
Production Inspection Sheet
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
Production Inspection Sheet 01/27/03
Page 19 of 25
OPERATION INSTRUCTIONS
PART NAME: PART NUMBER: KB JOB NUMBER:
0 0 0
OPERATION(S):
10 Progressive Complete
ISSUED BY: APPROVED BY:
DATE: DATE:
WORK STATION
OPERATION METHOD
OPERATOR
1) VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE.
PACKAGING INSTRUCTIONS
OP. 10 PRESS DIE
CONVEYOR TO CARDBOARD BOX
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
FIRST PIECE AND IN PROCESS INSPECTION
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.
Place part picture here
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.
8) USE YELLOW SCRIBE LINES TO VERIFY PROPER TRIM LOCATIONS.
7.
8.
6.
Form Revision: 10/04/04
Page 20 of 25
DIE SETUP SHEET

KB JOB NUMBER: PART NAME: CUSTOMER:
0 0 0
ISSUED BY: APPROVED BY:
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
Place picture of die in press here.

OFF
ON
OFF
TONNAGE REFERENCE DIE LOCATION TONNAGE LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR TOTAL TONNAGE SHAKER REFERENCE SIZE LOCATION
TYPE
COMMENTS 1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK. 2. 3. 4. 5. 6.
Page 21 of 25
Item ID 1 2 Micrometer 3 Tape Measure 4 5 6 7 8 9 10
Item Description 0-1" Mic - Material Thickness Verification Tape - Material Width Verification
SPECIAL CHARACTERISTICS LIST

PART NAME: PART NUMBER:
No. 1 2 3 4
Description/Rationale
Specification/Tolerance Class. -
Illustration/Pictorial
Page 23 of 25
Predictive Maintenance Check List

Die Number:
Indicate cycle 100,000 150,000 200,000 250,000 300,000 350,000 400,000 450,000 500,000 50,000
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
Do all activities marked with an "x"

Check/tighten screws Return to original sizes Check and/or replace Check and/or replace
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:
Actual Time Spent
Checklist Completed By:
PREVENTIVE MAINTENANCE WORK INSTRUCTION

Control Object: Reason: Responsibility: Use of this instruction will enable the Die Preventive Maintenance Areas to warrant the tools that have been PM'd as fit for service when returned to their production line. This instruction serves as a reminder to the die maker to check critical areas on the tools and repair/replace those areas that may be a problem during a production run. The die maker will perform this maintenance before returning the tools to production and inform the supervisor of any problem that requires scheduled release time to correct.
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:

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Our Name: Customer Name: Part Name: Part Number: Rev. Level: Rev.

Date: Product Program: Key Production Date:

Part Name: Part Number:

Part Submission Warrant

Buyer/Buyer Code MI Application

(if "No" - Explanation Required)

/ 8 hours. I have noted any deviations from this declaration below.

Fax No. Date

Part Functional Approval:

Production Part Approval ___ Dimensional Results

SUPPLIER TEST RESULTS

Production Part Approval ___ Dimensional Results

SUPPLIER TEST RESULTS

Production Part Approval ___ Dimensional Results

SUPPLIER TEST RESULTS

Production Part Approval ___ Dimensional Results

SUPPLIER TEST RESULTS

Production Part Approval ___ Material Test Results

PROCESS FLOW DIAGRAM PART NUMBER: PART NAME: CUSTOMER: E.C.L.:

MFG. ENG.: QUAL. ENG.: PLANT MGR.:

REV. DATE: 11/18/04

FAILURE MODES EFFECT ANALYSIS

PART NAME AND NUMBER: Rev Level/Date CORE TEAM MEMBERS:

PROCESS RESPONSIBILITY: KEY PRODUCTION DATE: MODEL YEAR(S) / VEHICLE(S):

FMEA DATE (ORIG.): FMEA DATE (REV.): PREPARED BY:

Detection Check at receiving

Incoming Inspection Load Coil on Uncoiler

Incorrect material Dimensional Incorrect alloy

Incorrect material Dimensional Clad on Wrong Side

Check Material Certification Check at Press

Progression set incorrectly Die Shut Ht. Incorrect Die Worn/Broken

Wrong Part # on Container Wrong "Born on Date"

FAILURE MODES EFFECT ANALYSIS PART NAME:

Detection Check at receiving

Incorrect material Dimensional

Non Conforming Product

PROCESS CONTROL PLAN

PART NUMBER/E.C.L.: / PART NAME: 0

PROTOTYPE PRE-LAUNCH PRODUCTION

DATE: _____________ DATE: _____________ DATE: _____________

Production Control Plan 11/1/04

Production Control Plan 11/1/04

Production Control Plan 11/1/04

Production Control Plan 11/1/04

Production Control Plan 11/1/04

Production Control Plan 11/1/04

Production Inspection Sheet

Production Inspection Sheet 01/27/03

ISSUED BY: APPROVED BY:

OP. 10 PRESS DIE

CONVEYOR TO CARDBOARD BOX

FIRST PIECE AND IN PROCESS INSPECTION

Place part picture here

8) USE YELLOW SCRIBE LINES TO VERIFY PROPER TRIM LOCATIONS.

Form Revision: 10/04/04

DIE SETUP SHEET

ISSUED BY: APPROVED BY:

Place picture of die in press here.

COMMENTS 1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK. 2. 3. 4. 5. 6.

Form Revision: 10/26/04

Item ID 1 2 Micrometer 3 Tape Measure 4 5 6 7 8 9 10

SPECIAL CHARACTERISTICS LIST

Form Revision: 11/3/04

Predictive Maintenance Check List

DATE: _______ DATE: _ DATE: _______