Customer: Customer Part Number: Supplier Part Number Part Name: Print Rev. Level: Drawing Dated: Doc.

Revision Date: Doc. Original Date: Doc revision: Project Engineer: Quality Engineer Purchasing Manufacturing Rep.: Document Prepared by:
What changed?

Your company name 1680995-101 1680995-101 Bushing, Guide Slot E 2/1/2003 N/A 12/23/2005 0 John Smith Amy Millimen Jane Doe Bob Miller Name
Document Name Date Who made change?

Bushings R US, Inc.

Supplying Quality Bushings - On Time - With Zero Defects - Is

Customer: Part Number: Part Name: Part Revision:

Your company name 1680995-101 Bushing, Guide Slot E

Bushings R Us, Inc

12345 Main St., Pleasantville, CA 98765 - ph: (123)456-7890

Bushings R US, Inc.

Index Warrant Letter Dimensional Layout Material & Performance Testing Capability Studies / MSA Process Flow Chart Control Plan PFMEA Marked Blueprint 1 2 3 4 5 6 7 8

Bushings R Us, Inc

12345 Main St., Pleasantville, CA 98765 - ph: (123)456-7890

Control Plan
Prototype Pre-launch Production
Key Contact/Phone Date (Original): Date (Revised): Control Plan Number: Part Number/Latest Change Level:

Robert Navarro
Core Team: John Smith

858-848-8000
Amy Millimen

12/23/2005

N/A

Customer Engineering Approval / Date (If Required):

1680995-101
Part Name / Description:

Bob Miller Jane Doe Supplier / Plant Approval / Date:

Customer Quality Approval / Date (If Required):

Bushing, Guide Slot

Supplier / Plant: Supplier Code: Part/ Process Number 10 Process Name/ Operation Description Incoming Inspection. Machine, Devices, Jig, Tools, For Mfg. n/a Receive to inventory and verify Physical properties 20 Order entry & Scheduling Customer Order Entry and Scheduling Process order and schedule manufacturing 30 Material handling Raw Bar Stock Pull from inventory per prodution work order 40 Machining Operation CNC Machining Center Raw Material, CNC Program Machine to drawing specifications Run CNC program for specified part. Verify critical dimensions per First Piece Inspection Plan. Visually verify correct program. Inspector to verify first piece per inspection plan. Ref. Procedure: Order Qty First Piece Set Up Ref. Procedure: Program Verification Dimensional Inspection Per Work Order Visual Qty per workorder Per Order Quantity/Lot Schedule based on machine & material availability. Ref. Procedure: Production Work Order Open PO Status Report One Per Order Quantity No. Characteristics Product Process
Special Char. Class

Other Approval /Date (If Required):

Other Approval / Date (If Required):

Methods Product / Process Specification/ Tolerance Bar Stock / Vespel SP-21 Mataerial Evaluation/ Measurement Technique Visual Inspection of Material Certification Ref. Procedure: Production Work Order Lot 100% Verify properties per Material Certification Quarrantine suspect material. Return to supplier. Notify Supervisor. Customer Service / Planner evaluates for feasibility. Revise schedule as required to meet requirements. Material Handlers pull per production workorder. Notify supervisor if discrepancy exists. Quarantine discrepant material. Scrap/Rework as appropriate. Size Sample Freq. Control Method Reaction Plan

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Control Plan
Prototype Pre-launch Production
Key Contact/Phone Date (Original): Date (Revised): Control Plan Number: Part Number/Latest Change Level:

Robert Navarro
Core Team: John Smith

858-848-8000
Amy Millimen

12/23/2005

N/A

Customer Engineering Approval / Date (If Required):

1680995-101
Part Name / Description:

Bob Miller Jane Doe Supplier / Plant Approval / Date:

Customer Quality Approval / Date (If Required):

Bushing, Guide Slot

Supplier / Plant: Supplier Code: Part/ Process Number 50 Process Name/ Operation Description Quality Control Key, Special, and Critical Dimensions Machine, Devices, Jig, Tools, For Mfg. 3 5 8 OAL Slot Width OD Verify Critical Dimensions No. Characteristics Product Process
Special Char. Class

Other Approval /Date (If Required):

Other Approval / Date (If Required):

Methods Product / Process Specification/ Tolerance 0.330" +/- 0.005 0.210 +/- 0.005 Evaluation/ Measurement Technique Calipers Calipers Gage Pin Diameter Gage 30 pcs. Initial annually PPAP and or customer requirements. Analyze cause for discrepancy, determine corrective action. per cavity. PPAP and Size Sample Freq. Control Method Reaction Plan

10 Slot Diameter

0.182 +/- 0.001 0.400 +/- 0.005

Ref. Procedure: In Process Inspection 3 5 8 OAL Slot Width OD 0.330" +/- 0.005 0.210 +/- 0.005 Calipers Calipers Gage Pin Diameter Gage One and per sampling plan First Piece and per sampling plan SPC Process Monitoring, intial set up verification process. Quarantine accumulated product. Scrap, or rework as required. 100% sort back to last control as needed. Correct process. Ref. Procedure: n/a Visual Defects Visual Inspection No scratches, burrs, burns, or other visual defects that may affect the performance of the product. Visual Per Order 100% Master Samples Quarantine accumulated product. Scrap, or rework as required. 100% sort back to last control as needed. Correct process. Ref. Procedure: 60 Packaging/Final Inspection n/a Barcode labels Check for accuracy Barcode label matches work order and production parts produced. Ref. Procedure: Visual inspection Two Each box. Per Work Order Inspector Packer Quarantine accumulated product. Rework as required.

10 Slot Diameter

0.182 +/- 0.001 0.400 +/- 0.005

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Control Plan
Prototype Pre-launch Production
Key Contact/Phone Date (Original): Date (Revised): Control Plan Number: Part Number/Latest Change Level:

Robert Navarro
Core Team: John Smith

858-848-8000
Amy Millimen

12/23/2005

N/A

Customer Engineering Approval / Date (If Required):

1680995-101
Part Name / Description:

Bob Miller Jane Doe Supplier / Plant Approval / Date:

Customer Quality Approval / Date (If Required):

Bushing, Guide Slot

Supplier / Plant: Supplier Code: Part/ Process Number 70 Process Name/ Operation Description Finished Goods scanning & storage 80 Pull from inventory & stage for shipment. n/a n/a Boxed parts. Dock Audit n/a Visually inspect for handling or storage damage. 90 Shipping n/a Quantity shipped to customer Visually inspect truck for suitability & load. n/a Load truck, have all documents signed as required. Pass / Fail. Visually inspect packaging. Visual Per truck. Each Shipment One Each box. Finished good request form, quarantine tag. Ref. Procedure: Shipping Report Packing slip, Bill of Lading Barcode scanner n/a Boxed parts per shipping report. Pull parts from stock & scan to shipment. n/a Machine, Devices, Jig, Tools, For Mfg. Barcode scanner n/a Boxed parts Scan parts to inventory n/a No. Characteristics Product Process
Special Char. Class

Other Approval /Date (If Required):

Other Approval / Date (If Required):

Methods Product / Process Specification/ Tolerance Scan barcode label for each box, verify box & scanned qty match. Scan barcode label for each box, verify box & scanned qty match. Visual One Each box. Evaluation/ Measurement Technique Visual One Each box. Inventory scan report detail, inventory verification form. Shipping Report shipment scanner repor.t Ref. Procedure: Warehouse personnel Analyze cause for discrepancy, determine corrective action Warehouse personnel Analyze cause for discrepancy, determine corrective action Warehouse personnel Quarantine product. Scrap, or rework as required. Warehouse personnel Reject Shipment and Notify Customer Size Sample Freq. Control Method Reaction Plan

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Potential Failure Mode Effects Analysis (Process FMEA)

FMEA Number Item 1680995-101 Bushing, Guide Slot Process Responsibility Key Date Amy Millimen John Smith Jane Doe Bob Miller Action Results S O Actions Taken
E V C C

1680995-101 Name 12/23/2005 (Rev.) 0 N/A

Prepared by FMEA Date(Orig.)

Model year(s)/Vehicle(s) Core Team: Process Function Potential Failure Mode Requirements 10 - Incoming Inspection Material Damaged

Potential Effect(s) of Failure

S E V

C S L A S

Potential Cause(s) / Mechanism(s)of Failure

O C C

Current Process Controls Prevention

Current Process Controls Detection

D E T

R P N

Recommended Action(s)

Responsibility & Target Completion Date

D E T

R P N

7 Receive Material Material unusable, Inventory Shortage, Late shipment of product

Damaged during shipping, improper material handling at supplier

N/A

Incoming Inspection

56

20 - Order Entry & Scheduling Receive production Data entry error. part orders & schedule part production runs. Process data accurately. 30 - Material Handling Pull raw material and Wrong material packaging from issued inventory and deliver to machining station 40 - Machining Operation. Machine Bushings Wrong program uploaded

Parts not scheduled to run(6).

Operator data entry error(1)

Orders received electronically, data entry not required.

Orders are double checked for accuracy where data entry required.

42

Quantity over run (3). Quantity under run (5).

Operator data entry error(2)

Orders received electronically, data entry not required.

Orders are double checked for accuracy where data entry required. Operator at machining station visually inspects material per work order.

42

Customer parts do not meet print material requirements(8)

Operator error reading work order/raw material packaging(1)

Raw material is bar code identified and scanned to the work order to verify correct.

48

Customer parts do not meet print dimensional requirments(8)

Operator error, wrong CNC program uploaded(2)

Operator verifies part number per First piece set up inspection per workorder and cross references drawing requirements to program part number.

16

Per customer requirements/dwg

Dimension does not meet print tolerance

Customer parts do not meet print dimensional requirements(8)

Bar stock not centered in chuck(2), machine tool is wearing(5), program requires adjustment(3)

First piece set up inspection

SPC monitoring per sampling plan

120

Implement Go/No-go Amy Millimen, gage for critcal 12/31/05 dimensions for 100% inspection

Gage 8 implemented, work instructions updated & operators trained.

64

50 - Quality Control Inspect Critical Dimensions Key, special or critical characteristics: 0.330" +/- 0.005 Dimension not to 0.210 +/- 0.005 print - over or 0.182 +/- 0.001 under size. 0.400 +/- 0.005

Potential fit problems with mating part too tight (6), or too loose (5), final assembly may not function(7) or function at less than optimal (6). Customer complaint or reject (7).

Deviation from established process(3), on any of the previously addressed variables (see section 40 above).

CNC program maintenance

PPAP layout and cap study, start-up inspection

84

Visual Defect

Customer complaint(7) / reject,Visually unappealing(5)

Tool Wear-heat damage(3), raw material porous/defective(1) Out dated bill of material data (1), Operator error, wrong part number entered in scale to set-up or to count box (2). Wrong labels supply with work order (1), operator error wrong label applied to box (1). Operator error (1), boxes stacked too high on skids (2)

Incoming inspection of material, PM of machine

In process inspection, incoming inspection

84

60 - Package / Final Inspection Final package for Incorrect quantity Customer complaint (7), finished parts, and of parts in box. incorrect inventory (5), over add to inventory. shipment (4), under shipment (7). Wrong barcode label applied to box. Add quantity of parts Container in each box, and damage receive to inventory without damage. 70 - Finished Goods Customer reject for wrong parts to the customer (7) incorrect inventory (5). Parts damaged (6), Customer complaint (7)

Inspector packer fills box & verifies piece count on scale compared to the barcode labels (6) Inspector packer fills box & verifies piece count on scale compared to the barcode labels (6) Internal stack height 4 boxes high (5), visual inspect for damage (7)

84

42

Operator tow motor training.

70

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Potential Failure Mode Effects Analysis (Process FMEA)

FMEA Number Item 1680995-101 Bushing, Guide Slot Process Responsibility Key Date Amy Millimen John Smith Jane Doe Bob Miller Action Results S O Actions Taken
E V C C

1680995-101 Name 12/23/2005 (Rev.) 0 N/A

Prepared by FMEA Date(Orig.)

Model year(s)/Vehicle(s) Core Team: Process Function Potential Failure Mode Requirements 10 - Incoming Inspection Boxes placed in wrong rack location.

Potential Effect(s) of Failure

S E V

C S L A S

Potential Cause(s) / Mechanism(s)of Failure

O C C

Current Process Controls Prevention

Current Process Controls Detection

D E T

R P N

Recommended Action(s)

Responsibility & Target Completion Date

D E T

R P N

Late (4) or missed shipment (5)

Warehouse personnel not following procedure (1), mis-scanned rack location (2). Operator error (1), boxes stacked too high on skids (2)

Computer system recommends Warehouse places parts per rack location via inventory parts computer recommendations, & list. Rack bays are all bar-coded. scans to rack location, scanned data downloaded into inventory. Operator tow motor training. Internal stack height 4 boxes high (5), visual inspect for damage (7) Finished skids are shrink wrapped with corner protectors. (4)

40

80 - Pull from inventory & stage to shipment. Pull from inventory Container Parts damaged (6), Customer per shipping report, damage complaint (7) and scan & stage for shipment.

56

Accurate data for both inventory & shipment purposes, boxes are staged without damage for shipment. 90 - Shipping Inspect & load parts on truck.

Unable to find parts for shipment.

Late (4) or missed shipment (5)

Warehouse personnel not following procedure (1), mis-scanned rack location (2).

Computer system identifies rack location from scanned inventory (4). Warehouse manager checks discrepant ship list daily & searches for anything missed (5).

40

Missing Paper work.

Late (4) or missed shipment (5)

Warehouse personnel not following procedure (1), special instructions listed on shipping report not followed (1). Operator error (1), boxes stacked too high on skids (2)

Special paperwork often faxed with advanced shipping notice (4). Truck drivers must review & sign packing slip & bills of lading at pick-up (4). Operator tow motor training. Internal stack height 4 boxes high (5), visual inspect for damage (5)

20

Truck to suitable to transport parts without damage.

Container damage

Parts damaged (6), Customer complaint (7)

70

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Process Flow
Customer: Part Number: Part Name: Your company name 1680995-101 Bushing, Guide Slot Document Created: Document Revised: Part Revision Level: 12/23/2005 N/A E

Process No.

Operation

Transport

Inspect

Store

Idle

10
Incoming Insp.

- Delivery of : Raw material, packaging items, components, and non stock items. - Incoming inspection. Documentation / Bills of lading checked, visual inspect for damage. samples taken & measured per incoming inspection plan. - Raw material / components are labeled after inspection. Inventory updated. - Received items moved to appropriate areas. - Order received from customer - Production Planning generates a work order according to open order maintenance and part classification criteria. - The work order & barcodes are posted to the production scheduling board. Mfg. enters order in the system per work order. - Warehouse personnel prints material issue slip. - Warehouse personnel pulls packaging, components, etc. required from appropriate rack location per Work Order requirements. - Material handler delivers to appropriate manufacturing location. - Set-up/Process Tech prints set up sheet, and loads appropriate CNC program per part number. - Set-up/Process Tech runs intial part and verifies criticals per set up instructions, making any adjustments necessary. - Process parameters are locked and the machining center is given approval to run. - Process Tech is to verify and document process settings on the Tracking Sheet. - Inspector packers pulls parts per sampling inspection plan and 100% visually inspects parts. - Quality Inspector performs in-process dimensional inspection of pulled parts per the sampling inspection plan and records data into the process monitoring system. - Accumulated production parts added to appropriate containers, per work order, and Job Instruction. - Box quantities confirmed via piece count or weigh scale. - Inspector Packer / Quality Inspector performs final visual check & seal boxes. - Material handler transports finished boxes to scan area in warehouse. - Warehouse worker verifies/scans barcode labels to inventory and places in assigned finished goods racks.

20 Order Entry & Scheduling 30 Finished Goods Packaging / Final Inspection 70 Production /Quality Control 60 Machining Operation 50 Material Handling 40

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Process Flow
Customer: Part Number: Part Name: Your company name 1680995-101 Bushing, Guide Slot Document Created: Document Revised: Part Revision Level: 12/23/2005 N/A E

Process No.

Operation

Transport

Inspect

Store

Idle

80 Pull from inventory & stage to shipment. 90 Shipping

- Customer Service issues shipping report, staged in Warehouse shipping board. - Warehouse personnel pull required quantities from finished goods and places in staging. - Boxes / containers are visually inspected for damage/deterioration. Barcodes are scanned from inventory and assigned to shipment. - Skids / boxes are wrapped etc per customer requirements. (corner protectors, allowed stack heights, etc.) - Truck arrives to pick-up shipment. - Shipping personnel visual inspect truck for suitability of transport. - Finished boxes loaded to truck. - Shipping personnel send advanced notice to customer.

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Part Submission Warrant

Part Name

Bushing, Guide Slot

Yes No NA Engineering Drawing Change Level

Part Number

1680995-101
Dated 2/1/2003

Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing no. Checking Aid No. NA

Dated N/A Purchase order No. Engineering Change Level NA Weight (kg) Dated NA
0.0891

1680995

SUPPLIER MANUFACTURING INFORMATION Bushings R Us Inc. Supplier Name 12345 Main St. Street Address Pleasantville, City Note: CA State 98765 Zip
6666666666

SUBMISSION INFORMATION Dimensional Customer Name / Division Buyer/ Buyer Code Application Material/Functional Appearance

Supplier Code

Your company name Don Anderson

Edge, Castle

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 REQUESTED SUBMISSION LEVEL (Check one) Level 1 Level 2 Level 3 Level 4 Level 5 Warrant, only (and for designated items, an Appearance Approval Report) submitted to customer. Warrant with product samples and limited supporting data submitted to customer. Warrant with product samples and complete supporting data submitted to customer. Warrant and other requirements as defined by customer. Warrant with 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 Additional Location Other - please specify

SUBMISSION RESULTS The results for dimensional measurements material and functional tests Yes No appearance criteria statistical process package

These results meet all drawing and specification requirements: Mold / Cavity / Production Process: DECLARATION CNC Machining

(If "No" - Explanation Required)

I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were 1200 / 8 hours. I have noted any deviations from this declaration below. produced at the production rate of EXPLANATION/COMMENTS: Dimension 1 does not meet print specification. Short term deviation is requested, with a new dimensional inspection and PSw to be submitted upon correction of discrepancy. Print Name Amy Millimen Title Quality Engineer Phone No. (123)456-7890 Date FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition: Customer Name Approved Other Customer Signature Rejected Part Functional Approval: Approved Waived Date FAX No. (123)435-7890

Supplier Authorized Signature

File Name: 168291664.xls.ms_office

DEVIATION REQUEST SHEET

PART NO: PART NAME: LOT NO: RESPONSIBILITY: PROGRESS X OF PARTS 1680995-101 Bushing, Guide Slot 123456 AMY MILLIMEN INITIAL MASS PROD. DATE: 12/24/2005 ISSUE NO. SUPPLIER NAME: BUSHINGS R US INC. TYPE OF DEVIATION LIMITED QUANTITY LIFETIME X LIMITED PRODUCTION DATE

DESCRIPTION OF NONCONFORMITY: Print item 1, chamfer width of 0.03" 0.01 measured oversized for 1 of 3 measured samples. We are requesting a temporary deviation to ship parts with this non-conformity until we exhaust the 300 piece PPAP sample parts produced. The feature is only oversized by 0.01", and will not affect the function of the assembly.

JUDGEMENT (FOR DELTA DESIGN USE ONLY) CATEGORY OF APPROVAL

LIMITED QTY
Quanitity:

LIMITED TIME
From/To Date:

PERMANENT

REASONS AND COMMENTS ENGINEERING SECTION

Judgement ACCEPT

SIGNATURE

RESPONSIBLE PERSON/DATE REJECT PERSON IN CHARGE/DATE QUALITY SECTION ACCEPT RESPONSIBLE PERSON/DATE REJECT PERSON IN CHARGE/DATE PURCHASING ACCEPT RESPONSIBLE PERSON/DATE REJECT PERSON IN CHARGE/DATE Customer Approval Required/ PPAP Submission Required No Customer Approval Required- No customer spec or drawing requirement

Production Part Approval Material Test Results

SUPPLIER PART NUMBER

Bushings R US
NAME OF INSPECTION FACILITY

1680995-101
PART NAME

Bushing, Guide Slot

TYPE OF TEST MATERIAL SPEC. NO./DATE/SPECIFICATION SUPPLIER TEST RESULTS OK NOT OK

Engineering Change Level: Specification Number: Date of Specification: Material Supplier: Material Description: Material Certification Date:

E Vespel SP-21 10/31/2001 Material Warehouse Vespel SP-21 12/01/2005

x x x x x x

SIGNATURE

TITLE

DATE

May 1995

CFG-1004

Qualilty Engineer

12/23/05

Production Part Approval Performance Test Results

Supplier BUSHINGS R US Name of Laboratory Part Number 1680995-101 Part Name Bushing, Guide Slot Ref. No. REQUIREMENTS

Page 14 of 20

Test Qty. Supplier Test Results and Test Conditions OK Freq. Tested

Not OK

No Performance Testing is Required

Signature

Title

Date

Production Part Approval Dimensional Results

SUPPLIER PART NUMBER

Bushings R Us
NAME OF INSPECTION FACILITY

1680995-101
PART NAME

Internal Inspection
Item Dimenson (in) Tolerance Type

Bushing, Guide Slot

Supplier Measurement Results
Sample 1 Sample 2 Sample 3 OK NOT OK

1a 0.03 1b 45 2 3 4 5 6 7 8 9 3.01 0.330 0.080 0.21 0.010 A Full Radius 0.400 TP 0.005

0.01 1.0 + 0.001 / -0.000 0.005 0.005 0.005

.05 45 3.010 0.332 0.082 0.211 0.008 OK

0.04 45 3.011 0.331 0.082 0.213 0.005 OK 0.400 0.003 0.182

0.03 46 3.011 0.33 0.08 0.212 0.006 OK 0.401 0.004 0.181 X X X X X X X X X X X

0.005

0.400 0.004

10 0.182

0.001

0.182 SEE MATERIAL CERT OK OK

11 Material Vespel SP-21 12 Edge Radius Callout Part Number, dash number, rev per 13 Delta standard.

OK OK

OK OK

X X

SIGNATURE

TITLE

DATE

Qualilty Engineer

12/24/05

Production Part Approval Initial Process Study

SUPPLIER PART NUMBER

Bushings R US
NAME OF INSPECTION FACILITY

1680995-101
PART NAME

Bushing, Guide Slot

Dimension: USL: LSL: 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 0.210 0.215 0.205 0.210 0.211 0.210 0.213 0.210 0.210 0.209 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.211 0.08 0.085 0.075 0.077 0.081 0.081 0.081 0.077 0.081 0.080 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.080 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.080 0.081 0.081 0.081 0.081

Production Part Approval Initial Process Study

SUPPLIER PART NUMBER

Bushings R US
NAME OF INSPECTION FACILITY

1680995-101
PART NAME

Bushing, Guide Slot

Dimension: USL: LSL: 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 0.210 0.215 0.205 0.211 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.210 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.209 0.211 0.210 0.211 0.210 0.210 0.210 0.209 0.209 0.210 0.210 0.211 0.212 0.208 0.208 0.209 0.212 0.210 0.209 0.210 0.211 0.210 0.209 0.208 0.210 0.211 0.212 0.210 0.210 0.08 0.085 0.075 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.081 0.080 0.081 0.081 0.081 0.078 0.077 0.077 0.081 0.081 0.080 0.081 0.082 0.081 0.077 0.078 0.079 0.081 0.081 0.081 0.081 0.081 0.081 0.080 0.081 0.078 0.081 0.080 0.078 0.081 0.081 0.080 0.081

Production Part Approval Initial Process Study

SUPPLIER PART NUMBER

Bushings R US
NAME OF INSPECTION FACILITY

1680995-101
PART NAME

Bushing, Guide Slot

Dimension: USL: LSL: 99 100 Mean Std Dev. Cp CpU CpL CpK 0.210 0.215 0.205 0.209 0.208 0.210 0.000887896 1.877097575 1.893991454 1.860203697 1.860203697 0.08 0.085 0.075 0.080 0.081 0.081 0.00106534 1.564445656 1.38296996 1.745921352 1.38296996 #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!

Part Number Dimension Tolerance Gage R&R Operator 1

1680995-101 0.210 0.005 1 0.21 0.21 0.21 0 0.21 0.211 0.21 0.001 2 0.21 0.21 0.21 0 0.21 0.21 0.21 0 3 0.213 0.213 0.213 0 0.212 0.212 0.213 0.001

Gage Type: Calipers Gage ID: Cal0010 Date: 12/23/2005 4 0.21 0.211 0.211 0.001 0.21 0.211 0.211 0.001 5 0.211 0.211 0.211 0 0.211 0.21 0.211 0.001 6 0.21 0.21 0.21 0 0.21 0.21 0.21 0 7 0.21 0.21 0.21 0 0.211 0.21 0.21 0.001 8 0.21 0.211 0.211 0.001 0.21 0.211 0.211 0.001 9 0.21 0.21 0.21 0 0.21 0.21 0.21 0 10 Average 0.21 0.21 0.21 0.21053 0 0.0002 0.21 0.21 0.21 0.2105 0 0.0006

Operator 2

Operator 3 (if only 2 ops, Clear C11:L13) Part Range Average XDiff UCL LCL Repeatability Reproducibility Gage Capability Spec Tolerance Acceptability(%)

Trial 1 Trial2 Trial 3 Range1 Trial 1 Trial2 Trial 3 Range2 Trial 1 Trial2 Trial 3 Range3 K3 Averages 0.0004 0.0000 0.0010 0.0000 0.0012 0.0001 0.0012 0.0200 0.06

Xbar1 Rbar1

Xbar2 Rbar2

Xbar3 Rbar3 0.210 3.65 0.210 2.7 0.213 2.3 0.211 2.08 0.211 1.93 0.210 1.82 0.210 1.74 0.211 1.67 0.210 1.62 0.210 0.003 Range of Part Averages

Constants 2 Trials 3 Trials # Trials 3.27 2.58 D4 0 0 D3 4.56 3.05 K1 3.65 2.7 K2 2 Ops 3 Operators

2 2.58 0 3.05 3.65

UCL represents the limit of the individual R's Circle those beyond the limit. Identify and correct causes LCL = 0 D3=0 for up to 7 trials

AIAG - Automotive Industry Action Group Formulas EV 0.0012 %EV 27.2% # Parts #Trials AV: 0.00000 10 3 %AV 0.0% R&R 0.0012 %R&R 27.2% PV 0.0043 %PV 96.2% TV 0.0045

Equipment Variation (EV) % of Total Variation (TV) Appraiser Variation(AV) % of Total Variation (TV) Repeatability and Reproducibility (R&R) % of Total Variation (TV) Part Variation (PV) % of Total Variation (TV) Total Variation (TV)

Gage system may be acceptable based on importance of application and cost Instructions Just enter your measurement data in Cells C3:L5, C7:L9, C11:C13 The template will automatically calculate all of the values based on your data

Gage Repeatability and Reproducibility Measurement is one common cause of variation. Gage R&R helps improve measurement If repeatability is large compared to reproducibility, reasons include: 1. gage instrument needs maintenance 2. gage needs to be redesigned 3. clamping or location needs to be improved 4. excessive within-part variation If reproducibility is large compared to repeatability, reasons include: 1. Operator needs to be better trained inhow to use and read gage 2. Calibrations on gage are not clear 3. Fixture requred to help operator use gage more consistently Gage System Acceptability %R&R<10% %R&R<30% %R&R>30%

Gage System Okay May be acceptable based on importance of application and cost of gage or repair Gage system needs improvement