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How To - Insert a Document
To insert a document in the UPPAP evidence package:
1. Go to the worksheet where you need to insert document
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ASQR-09.2 REVISION CONTROL INSTRUCTION: Any iteration and/or resubmission of this evidence package shall be documented in the revision table below. UPPAP Submission submitted to Member First Production Delivery Date: Level: UTC Member Focal UTC Contact UTC Contact Point (MFP): Phone Number: E-Mail Address: Objective Evidence Package Revision: Revision Date Submitted by Description .3.2 Form 1 with complete supporting data for all Elements per 5. UTC Division: UPPAP PACKAGE COVER SHEET Supplier Contact Supplier Name: Supplier Code: Email Address: Supplier Contact Supplier Contact Name: Drawing Revision #: Phone Number: Part #: Part Name: Reason for UPPAP Initial Drawing / Part Revision: Submission: Submission Date: Level 3 . INSTRUCTION : This document may be used to submit objective evidence of having met the requirements of ASQR-09.2.

UTC .UPPAP Evidence P Part Number: 0 Drawing Revision: 12/30/1 Part Name: 0 Product Definition 1 Released Production Drawings or Definition 11 Engineering 2 Supplementary Product Requirement Documents Approval 3 Production Purchase Order 13 Functional UPPAP Core Elements 4 Design Risk Analysis 14 Special Pro 5 Process Flow Diagram 16 Member D 6 PFMEA 17 Parts Mark 7 Process Control Plan 18 Packaging 8 Process Readiness Study (PRS) .

8 Process Readiness Study (PRS) 9 Initial Process Studies 10 Measurement System Analysis (MSA) 12 Dimensional Reports 15 Material Certification Documentation 19 Review an .

Preservation and Labeling Approval .ence Package 12/30/1899 UPPAP Special Elements Activities Engineering Frozen Planning / Engineering Source Approval Functional Testing Approval Required Approvals Special Processes & NDT Approval Member Defined Raw Material Approval Parts Marking Approval Packaging.

Formal Approval Review and Sign-Off .

the revision of the model shall be verified and documented in the UPPAP File.2): The Supplier shall ensure the product has been manufactured to a production released design definition and the drawing revision aligns with the PO requirement. OBJECTIVE (ASQR-09. The Supplier shall include a copy of the verified product drawings in the UPPAP File. bill of material and the Member’s associated drawing in the UPPAP File. Applicable internal and external specifications shall be readily available.2) INSTRUCTIONS: Include a legible copy of the production released design definition. UPPAP EVIDENCE PACKAGE (ASQR 09. Where digital product definition is applicable. DRP Suppliers shall include a copy of their current drawing. For Design Responsible Producers see below. Member Specific Reference Guide: Part Number: 0 Part Revision Level: 12/30/1899 Part Name: 0 Fillable below this line .

2) design definition and the here digital product UPPAP File. ber’s associated drawing 12/30/1899 . UPPAP EVIDENCE PACKAGE (ASQR 09.

The Supplier shall include a copy of the verified SPRD in the UPPAP File.INSTRUCTIONS: A copy of the SPRD shall be included in the UPPAP evidence file.2): The Supplier shall ensure that the product has been manufactured to production released SPRD and that the document revision aligns with the PO and product definition requirement. Member Specific Reference Guide: Part Number: 0 Part Revision Level: 0 Part Name: 0 Fillable below this line . OBJECTIVE (ASQR 09.

Member Specific Reference Guide: Part Number: 0 Dwg Revision 0 Part Name: 0 Fillable below this line . OBJECTIVE (ASQR 09. The Supplier shall include a copy of the production PO or contract in the UPPAP File. shall be included in the UPPAP evidence package.2): The Supplier shall ensure that the product has been manufactured to a production PO or other contractual document and all product definition revisions align with those referenced on the PO or contract. along with the anticipated peak production rate as communicated by the Member.INSTRUCTIONS: A copy of the entire Production Purchase Order being delivered against.

The Supplier shall ated peak production rate 0 .d in the UPPAP evidence r other contractual ontract.

2 Form 3. A copy of the UTC member provided ASQR-09.Design Risk Analysis INSTRUCTIONS: A complete Design Risk Analysis (DRA) or a summary of results (e. Note 1: DRAs may be derived from part family DRAs as long as any unique product characteristics have been reviewed and included. Product KCs defined by design to control identified risks and any additional features shall be communicated to the Supplier via the product definition using ASQR-09. Any product related risks that may be affected by the manufacturing process and cannot be eliminated through the design shall be communicated to the Supplier as product KCs via the product definition using ASQR-09.2 Form 3 .2 Form 3. durability. prioritized and completed. Note 2: DRPs may use the ASQR-09. reliability. assembly and manufacturability is executed and appropriate mitigation activities are identified. OBJECTIVE (ASQR 09. Any Build-to-Print (BTP) Supplier shall include the latest copy of ASQR-09.2 Form 3 in the UPPAP File.IDS shall satisfy this requirement for non-DRP suppliers.2 Form 3 to communicate product and process KCs defined to control identified risks to all levels of its supply chain. The Supplier shall include evidence of the risk analysis in the UPPAP File.2): DRPs shall ensure that a Design Risk Analysis methodology related to performance. A Design Failure Modes and Effect Analysis (DFMEA) per SAE J1739 or other DRA that achieves the same objectives shall be used.Element 4 . Member Specific Reference Guide: .g. list of recommended action items etc. or equivalent means. or Member equivalent means.) shall be included in the UPPAP evidence package.

Tools: Fillable below this line .

Member Specific Reference Guide: Tools: Fillable below this line .2): The Supplier shall create a Process Flow Diagram or equivalent to facilitate the development of a robust PFMEA and Control Plan. OBJECTIVE (ASQR 09. Note 2: The Supplier should consider the maximum expected volume as communicated by the Member to define the process flow. The Supplier shall include a copy of the Process Flow Diagram in the UPPAP File.Element 5 . KPC-M) Note 1: Process Flow Diagrams may be derived from part family diagrams as long as any unique processing steps and characteristics have been reviewed and included.Process Flow Diagram INSTRUCTIONS: A copy of the process flow chart for the part shall be included in the UPPAP package. The Process Flow Diagram shall include: • Production process steps and sequences from receiving material to shipment of end product • Standardized flowchart symbols • Alternate process paths and formal rework loops • Outside operations • Transportation and handling • Key inputs and outputs of each process step • Identification of steps that impact product or process KCs including any additional features identified in the DRA or on the IDS and Supplier identified process KCs (e.g.

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• Features identified in the DRA or on the IDS • Supplier identified process KCs (e. KPC-M) • Product family quality history. a summary of the analysis and results shall be included in the UPPAP package and may require an onsite visit by the member. document and maintain the part or assembly PFMEA and ensure consideration of the following: • Process Flow Diagram alignment • Product features.Process Failure Mode and Effects Analysis INSTRUCTIONS: The complete PFMEA shall be included in the UPPAP package. KCs etc. escapes and lessons learned. Note: PFMEA’s may be derived from part family PFMEA’s as long as any unique product characteristics and/or processing steps have been included.2): The Supplier shall ensure risks associated with the manufacturing or assembly process have been identified and mitigated using a PFMEA per SAE J1739 (or an equivalent process that achieves the same objectives).Element 6 . Member Specific Reference Guide: Tools: Fillable below this line . including but not limited to non-conformances. tolerances. The Supplier shall develop.g. OBJECTIVE (ASQR 09. In case of intellectual property issues. The Supplier shall include a copy of the PFMEA in the UPPAP File.

$$$ 5 $$ 3 $ 1 .

The Process Control Plan shall be used to ensure sustained process control throughout the manufacturing life of the part and/or assembly.Process Control Plan INSTRUCTIONS: A complete Process Control Plan shall be included in the UPPAP evidence package. etc. Note: Control Plans may be derived from part family Control Plans as long as any unique product characteristics and/or processing steps have been included. Key Process Inputs (KPIs) and associated controls.Element 7 . Member Specific Reference Guide: Tools: . OBJECTIVE (ASQR 09. set-up inspections. The Process Control Plan shall identify the product and process KCs.) • Reaction Plans The Supplier shall include a copy of the Control Plan in the UPPAP File.2): The Supplier shall ensure any manufacturing risks are adequately controlled by developing a Process Control Plan (refer to UTCQR-09.1). The Process Control Plan shall include: • Operation/process step where any product or process KC is measured • Specification/tolerance for all product and process KCs • Measurement system used • Sample size and frequency • Control method (type of control chart.

Fillable below this line .

$$$ 5 $$ 3 $ 1 .

fixtures. Note: PRS’s may be derived from part family PRS’s as long as any unique product characteristics and/or processing steps have been included. refer to Appendix A. Member Specific Reference Guide: . manufacturing equipment and gages • Operation work instructions • Process control methods • Gage suitability (discrimination. OBJECTIVE (ASQR 09.2): The Supplier shall ensure its manufacturing process will meet the production requirements at projected full demand rate by completing a Process Readiness Study representing all levels of its supply chain that includes: • Manufacturing process steady state . detection and removal of foreign objects The Supplier shall include a copy of the PRS in the UPPAP File. applicability etc.) • Total Productive Maintenance (TPM) program • Supply Chain management • Prevention.tools. Where no Member specific requirement is invoked in Appendix A.INSTRUCTIONS: A color copy of the completed Process Readiness Study shall be included in the UPPAP package. For any additional Member specific requirements. the “UTC Process Readiness Study self-assessment tool” or equivalent may be used. Note: A PRS may be performed with a Member representative or as a self-evaluation based on Member guidelines.

Part Number: 0 Dwg. Revision Level: 0 Part Name: 0 Fillable below this line .

In addition. Any exception to this requirement shall be approved by the MFP and documented on ASQR-09. Measures of process capability other than Cpk may be used only if such measures have received documented approval by the MFP. setup to setup.2 Form 1.g. If using attribute data.g.Element 9 . machine to machine. group.33 . The UPPAP File shall contain documented evidence that initial process studies have been conducted for all product and process KCs including any substitute KCs and additional features identified on the ASQR-09. Any out-of-tolerance or out-of-control conditions shall be addressed by the Supplier. use of short run SPC techniques (e.2 Form 3 and Supplier identified process KCs (e. For any additional Member specific requirements.The process currently meets requirements. data collected from development or pre-production parts can be considered. refer to UTCQR-09. KPC-Ms) shall be included in the UPPAP package.1 to establish the capability index. exponential.1. KPC-Ms).2 and Member defined specifications or procedures for raw material dimensional qualification and process monitoring requirements. For UTC Supplier sampling requirements. If a conflict arises between ASQR-09. Variable data shall be used wherever feasible. Acceptance Criteria: The Supplier shall use the following as acceptance criteria for evaluating initial Process Study results.2 Form 3 and Supplier identified process KCs (e. Note 4: Execution of this UPPAP Element does not automatically grant any sampling authorization. equipment and processes intended for production are used. .2 Form 1. OBJECTIVE (ASQR 09. Weibull. time to time and lot to lot. Cpk < 1. a complete SPC Control Chart for each KC shall be included to demonstrate the result with the supporting data readings. Note 2: Process variation includes variability associated with piece to piece.The process does not currently meet the acceptance criteria.g. in statistical control and the requirements of Element 10 (MSA) have been met. part family charts) may be allowed to meet the 25 part minimum requirement (where full production run is less than 25 parts or 25 parts will take an unreasonable amount of time).Initial Process Studies INSTRUCTIONS: A complete listing of the capability results for all product KCs including any substitute KCs and additional features identified on the ASQR-09. target. refer to ASQR-20. etc. Note 3: With MFP agreement of the approach and source of data. Results Interpretation Cpk ≥ 1. Note 1: Provided the same tooling. Contact the MFP to review the process study results and propose necessary process and control plan improvements. Process capability indices shall only be calculated after the process is determined to be stable. refer to Appendix A.2): The Supplier shall conduct an initial capability study of the manufacturing processes used to produce all product and process KCs. Data shall be captured from a minimum of 25 consecutive parts representing process variation approved by the MFP and documented via ASQR-09.). the latter shall take precedence.33 . The capability indices shall be calculated using the appropriate distribution that the process represents (normal.

Member Specific Reference Guide: Part Number: 0 Dwg. Revision Level: 0 Part Name: 0 Tools: Fillable below this line Initial Process Study Quantity of Feature parts used to Item # KC Type Cpk Result Action Plan Description calculated Cpk value 1 2 3 4 5 6 7 8 9 … .

.

Target Completion Responsibility Date .

try-out reports. MFP acceptance of any mitigation plan is required. stability.2): The Supplier shall ensure adequacy and applicability of the measuring systems to evaluate and monitor product and process KCs. The following criteria shall be used to determine acceptance of the measurement system: Pass/Fail: Kappa >= 0. Any Gage R&R studies shall have a Precision-to-Tolerance (P/T) ratio ≤ 20% unless a lower maximum ratio is required by the Member. the Supplier shall provide a mitigation plan which ensures conformity of product. The use of the applicable member focal point R&R capability tools available in the supplier portal and/or MINITAB may to be used. Member Specific Reference Guide: . When P/T ratio is not achieved. The UPPAP File shall contain copies of the Measurement Systems Analysis (including Gage R&R) conducted on all instruments used for measuring all product and process KCs.75. Note: MSA’s may be derived from part family MSA’s as long as any unique product characteristics and/or processing steps have been included. evidence of inspection and acceptance testing (gage inspection. Where attributes are used to assess feature acceptability (e.g.Measurement Systems Analysis INSTRUCTIONS: A complete listing of all MSA studies (including supporting data) shall be included in the UPPAP package. OBJECTIVE (ASQR 09.g. For custom designed gaging.Element 10 . or discrimination. pass/fail criteria) the evaluation of measured variable data is not possible. repeatability. etc. Ordinal: ICC >= 0. any additional features identified on the ASQR-09. or when other deficiencies are identified such as bias.2 Form 3 and Supplier identified process KCs (e.8. KPC-M).) shall also be included in the UPPAP File. linearity.

Revision Level: 0 Part Name: 0 Tools: Fillable below this line MEASUREMENT SYSTEMS ANALYSIS SUMMARY TABLE FOR UPPAP Characteristic Gauges Results Act Precision to Feature Gauge Gage R&R Gage R&R Item # KC's type Tol.Part Number: 0 Dwg. Gauge # Gauge Name Tolerance Actions Description Resolution Type Capability % (Bias) 1 2 3 4 5 6 7 8 .

9 … .

Action plan Target Completion Responsibility Date .

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The Supplier shall include in the UPPAP File appropriate evidence showing conformance to the EFP/ESA requirements. Revision Level: 0 Part Name: 0 Fillable below this line . For any additional Member specific requirements.2): The Supplier shall validate that all Engineering Frozen Planning (EFP) or Engineering Source Approval (ESA) requirements are met when invoked by a Member specification. refer to Appendix A of ASQR-09. Member Specific Reference Guide: Part Number: 0 Dwg. OBJECTIVE (ASQR 09.2. INSTRUCTIONS: A copy of the ESA signature page shall be included in the UPPAP package.

time to time and lot to lot variation considering all unique process streams.Dimensional Reports INSTRUCTIONS: A copy of the approved FAI shall be included in the UPPAP package. setup to setup. Note 1: In-process gaging or automated inspection may be used to capture this data. For any additional Member specific requirements.2): The Supplier shall create a minimum of 5 dimensional reports listing variable results for all drawing features with tolerances from strategically selected parts (AS9102 Form 3 or equivalent form may be used). the latter shall take precedence. 4 additional dimensional reports (Form 3) for parts randomly selected shall also be included. Member Specific Reference Guide: Part Number: 0 Dwg. The Supplier shall submit AS9102 Form 3 from this FAIR in the UPPAP package as the first dimensional report requirement for Interim or Full Approval. Note 2: Execution of this element does not automatically grant any sampling authorization. OBJECTIVE (ASQR 09. In addition.1. machine to machine. For UTC Supplier sampling requirements. If a conflict arises between ASQR-09.Element 12 . Strategically selected parts shall be sampled over a sufficient time to capture variability associated with piece to piece. refer to ASQR-20.2 and Member defined specifications or procedures for raw material dimensional qualification and process monitoring requirements. refer to Appendix A of ASQR-09. Any out-of-tolerance. Revision Level: 0 Part Name: 0 Fillable below this line . Note 3: The four (4) additional dimensional reports are not required to be FAIR’s. The UPPAP File shall contain a copy of the approved First-Article Inspection Report (FAIR) prior to shipping production parts. out-of-control or trending towards out-of-tolerance conditions shall be addressed by the Supplier.2.

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INSTRUCTIONS: A copy of the approved Acceptance Test Procedure and the test results for 1 part shall be included in the UPPAP package. Test results for quantities required in the referenced specification shall be retained in the UPPAP File.2): When required by Member specification. Revision Level: 0 Part Name: 0 Fillable below this line . the Supplier shall validate that all functional tests have been approved and requirements have been met. The MFP may request additional functional test sampling. OBJECTIVE (ASQR 09. Member Specific Reference Guide: Part Number: 0 Dwg.

2): The Supplier shall validate that all Special Process and NDT Approval requirements are met. The Supplier shall include in the UPPAP File: Note: Reflect special processes requiring lab qualification and NDT approvals on the Certificate of Conformity (CofC). OBJECTIVE (ASQR 09.INSTRUCTIONS: Evidence of Special Process / NDT approval of the site and part number specific NDT approval and/or approval by Supplier with Design Responsibility shall be included in the UPPAP package. Member Specific Reference Guide: Part Number: 0 Dwg. Revision Level: 0 Part Name: 0 Fillable below this line .

INSTRUCTIONS:
Provide a copy as evidence to show that the material was procured from a Member approved
source or include a copy of the test results for material sourced from a non approved source and
tested and approved by a Member approved test facility.

OBJECTIVE (ASQR 09.2):
The Supplier shall validate that all Material Certification requirements are met.
The Supplier shall include in the UPPAP File:
• For BTP parts, documented evidence that the material used was purchased from a Member
approved source when required.
• For DRP parts, provide evidence that the Supplier utilizes approved sources for material and a
copy of the Certificate of Conformity (CoC). If material is from a non-approved source, provide
copies of the material test reports and results obtained through an approved Member test facility
when required.

Contact the MFP if the above conditions are not met.

Member Specific Reference Guide:

Part Number: 0 Dwg. Revision Level: 0

Part Name: 0

Fillable below this line

The Member approved dimensional report shall be retained in the UPPAP File and the Supplier shall include a copy
of the approval of this report in the UPPAP package.

OBJECTIVE (ASQR 09.2):
For Member defined raw material such as castings, forgings, or other raw material, the Supplier shall verify that all
specified dimensional requirements are met.

The Member approved dimensional report shall be retained in the UPPAP File and the Supplier shall include a copy
of the approval of this report in the UPPAP package.

Member Specific Reference Guide:

Part Number: 0 Dwg. Revision Level: 0

Part Name: 0

Fillable below this line

INSTRUCTIONS:
The Supplier shall include evidence of Member approval and a photograph of the approved part
marking in the UPPAP File.

OBJECTIVE (ASQR 09.2):
The Supplier shall ensure all Member part marking requirements are met by obtaining part marking
approval from the Member. The Supplier shall include evidence of Member approval and a
photograph of the approved part marking in the UPPAP File.

Member Specific Reference Guide:

Part Number: 0 Dwg. Revision Level: 0

Part Name: 0

Fillable below this line

.

Preservation and Labeling may be derived from part family Packaging. OBJECTIVE (ASQR 09. Preservation and Labeling as long as any unique product characteristics and/or processing steps have been included. The Supplier shall include evidence of Member approval in the UPPAP file.2): The Supplier shall verify that the production intended packaging meets the Member defined specifications by obtaining packaging approval from the Member. Revision Level: 0 Part Name: 0 Fillable below this line . INSTRUCTIONS: A copy of the pre-approved Packaging form. specific to the part number shall be included in the UPPAP package. Note: Packaging. Member Specific Reference Guide: Part Number: 0 Dwg.

complete ASQR-09.2 Section 5. OBJECTIVE (ASQR 09. INSTRUCTIONS: The completed and signed UPPAP Form 1 for the this package shall be submitted.2 Form 1 for each part number unless otherwise approved by the MFP • Approve the submission of UPPAP Packages and any deviations to the requirements of this procedure for all levels of its supply chain • Include the ASQR-09. Revision Level: 0 Part Name: 0 Fillable below this line .2 Form 1 and submit to the MFP for approval along with the necessary UPPAP Package based on the Submission Level • Complete a separate ASQR-09.1b) in the UPPAP Package Member Specific Reference Guide: Part Number: 0 Dwg.2): The Supplier shall: • Verify all measurement and test results show conformance with Member requirements • Ensure all required documentation is available and maintained within the UPPAP File • Review all applicable data for content and accuracy before submitting the UPPAP Package for approval • Upon a satisfactory internal review. Note: It can be attached below or submitted as a separate attachement with this package.2 Form 1s from all levels of its supply chain (as defined in ASQR-09.

00000 #N/A 42 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 7 #N/A #DIV/0! #N/A #N/A #N/A 0.267 1.00000 #N/A 33 #N/A #DIV/0! #N/A #N/A #N/A 0.223 1.568 4 0.00000 #N/A 13 #N/A #DIV/0! #N/A #N/A #N/A 0.089 6 0.00000 #N/A 0. PROCESS CAPABILITY CALCULATIONS Number of samples (<= 50) 0 Nominal specification Sample size for moving range(2 .114 2.118 1.00000 #N/A Individuals (X) Chart Upper control limit Center line 9 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 Observation number Control Chart Factors n A2 D3 D4 d2 A3 B3 B4 2 1.577 0 2.00000 #N/A 10.182 0.00000 #N/A Lower control limit 10 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 0.483 0 2.30000 0.0000 11 #N/A #DIV/0! #N/A #N/A #N/A 0.534 1.078 0.716 .136 1.267 3 1.60000 47 #N/A #DIV/0! #N/A #N/A #N/A 0.184 1.574 1.00000 #N/A 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 28 #N/A #DIV/0! #N/A #N/A #N/A 0.693 1.00000 #N/A 21 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 15 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 0.326 1.00000 #N/A 24 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 0.70000 45 #N/A #DIV/0! #N/A #N/A #N/A 0.032 0.00000 #N/A #N/A #N/A Average #DIV/0! Standard Deviation #DIV/0! Moving Observation Value LCLx CLx UCLx Range LCLr CLr UCLr Cp #DIV/0! 1 #N/A #DIV/0! #N/A Cpl #DIV/0! 2 #N/A #DIV/0! #N/A #N/A #N/A #N/A #N/A Cpu #DIV/0! 3 #N/A #DIV/0! #N/A #N/A #N/A 0.954 0 2.864 2.975 0.Process Capability and Individuals & Moving Range (IX-MR) Chart Part Number: Drawing Number: Drawing Zone: Part Name: CTQ Feature: This spreadsheet is designed for up to 50 observations and a moving range from 2 to 5.00000 #N/A 0.00000 #N/A Value 12 #N/A #DIV/0! #N/A #N/A #N/A 0.059 1.00000 #N/A 2.00000 #N/A 1.90000 43 #N/A #DIV/0! #N/A #N/A #N/A 0.373 0.50000 48 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A Mo ving ranges 38 39 #N/A #N/A #DIV/0! #DIV/0! #N/A #N/A #N/A #N/A #N/A #N/A 0.97 7 0.419 0.815 9 0.0000 27 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 37 #N/A #DIV/0! #N/A #N/A #N/A 0.266 5 0.88 0 3.239 1.00000 #N/A Individuals 8 #N/A #DIV/0! #N/A #N/A #N/A 0.023 0 2.00000 #N/A 5 #N/A #DIV/0! #N/A #N/A #N/A 0.0000 25 #N/A #DIV/0! #N/A #N/A #N/A 0.659 0 3.00000 #N/A M o v in g ra n g e s 31 #N/A #DIV/0! #N/A #N/A #N/A 0.099 0.761 10 0.5) Upper tolerance limit Lower tolerance limit Grand Average #DIV/0! D3 D4 D2 Average Range 0.308 0.076 1.00000 #N/A Cpk #DIV/0! 4 #N/A #DIV/0! #N/A #N/A #N/A 0.97 1.816 2.337 0. Then enter your data in the "Value" Column beginning with Cell B17.777 3.287 0.00000 #N/A 32 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 8.00000 #N/A #N/A Moving Range Chart Lower control limit Center line Upper control limit 40 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 0.0000 19 #N/A #DIV/0! #N/A #N/A #N/A 0.284 1.00000 #N/A 36 #N/A #DIV/0! #N/A #N/A #N/A 0.40000 49 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 12.00000 #N/A 46 #N/A #DIV/0! #N/A #N/A #N/A 0.729 0 2.128 2.00000 #N/A 50 #N/A #DIV/0! #N/A #N/A #N/A 0.185 1.00000 #N/A 0. Enter the sample size in cell E10.847 1.00000 #N/A 29 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 23 #N/A #DIV/0! #N/A #N/A #N/A 0.882 8 0.00000 #N/A 35 #N/A #DIV/0! #N/A #N/A #N/A 0.0000 22 #N/A #DIV/0! #N/A #N/A #N/A 0.10000 0.282 2.00000 #N/A 6 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 0.0000 14 #N/A #DIV/0! #N/A #N/A #N/A 0.03 1.0000 17 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 20 #N/A #DIV/0! #N/A #N/A #N/A 0.004 2.00000 #N/A 26 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 4.20000 0.80000 44 #N/A #DIV/0! #N/A #N/A #N/A 0.704 1.00000 #N/A 18 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A Observation number 30 #N/A #DIV/0! #N/A #N/A #N/A 0.924 2.00000 #N/A 16 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 #N/A 34 #N/A #DIV/0! #N/A #N/A #N/A 0.00000 41 #N/A #DIV/0! #N/A #N/A #N/A 0.628 0 2.427 0 2.00000 #N/A 0.00000 #N/A 6.

Record results below.000000 1) GAGE CAPABILITY (GC) FOR PRODUCT ACCEPTANCE (% of Engineering Tolerance) GC as a % of Eng. Operator A Operator B Range Part 0 0 1 0. Tolerance Range) * 100 = #DIV/0! * SPECIAL SUPPLIER NOTE: Supplier needs to enter "Product Sigma" into HS Process Certification Database when creating a new Gage File for any HS defined KPCs/TKCs.000000 * See special Supplier Note below NOTE: d2 = 2.00000 * 4.000000 NOTE: CV = Combined Variability used to calculate Process Tolerance Product Sigma = Rbarm/1.000000 RbarCV = (RA+RB)/2 = 0.000000 RA (Range of 5 values) = 0.000000 Rbarm = Sum/5 0.000000 Sum of 5 ranges 0.000000 RB (Range of 5 values) = 0.000000 Process SigmaCV = RbarCV/d2 = 0. 2) GAGE CAPABILITY FOR CONTROL CHART PURPOSES (% of Process Tolerance) % of Process Tolerance = (R&R / 6 x SigmaCV) * 100 = #DIV/0! LEGEND ACCEPTABLE MARGINAL UNACCEPTABLE . Tolerance: Instructions: 1) Type in shaded areas only. 3) Have two operators measure each part independently.000000 5 0. Gage R&R Short Form Study (1 time / 2 Operators x 5 parts) Gage Name: Part Number: Performed By: Gage Number: Part Name: Operator A: Graduations: Operation Number: Operator B: Zero Equals: Characteristic: Area: Unit of Measure: Specification: Date: Total Eng.000000 4 0. 2) Select 5 parts at random and number them 1 through 5. 4) Analyze the results to determine variability due to both Repeatability and Reproducibility. Enter the Product Sigma into the database field entitled "Gage RR Std Deviation".000000 2 0.19 = 0.000000 3 0.000000 0.326 for n=5 Gage R&R for Product Acceptance = Rbarm * 4. Tolerance = (Gage R&R / Total Eng.33 = 0.33 Process Tolerance = 6 * Sigma CV = 0.

Units Today's Date Gage # GageType Part # Total Tol.0000 4 0.equipment variation Rbar = 0 Rbar = #DIV/0! Rbar = 0. 2nd Meas.0000 Area: 2 0.operator & equipment variation combined Std dev of Combined = #DIV/0! USE FOR CONSIDERATION OF ACCEPTANCE Percent of Spread/Tolerance Consumed by Gage R&R OR REJECTION OF THE MEASURING DEVICE.0000 0. #DIV/0! %OF TOL.0000 0. # Dimension Performed By: OPERATOR A: 0 OPERATOR B: 0 Operator A: Sample 1st Meas. 3) Have two operators measure each part independently.0000 3 0.0000 5 0.operator variation Repeatability . = #DIV/0! ** ** Question results if > 20% .0000 0. 4) Repeat measurement process for each operator.0000 0. Record results in '1st Measurement' cells below. #DIV/0! Test for Strays COMMENTS: UCL = 0 Reproducibility & Repeatability . 2) Select 5 parts at random and number them 1 through 5. 2nd Meas. Record results in '2nd Measurement' cells below. Range 1st Meas. = Date of Study Op.0000 0.000000 s= 0 s= #DIV/0! s= 0 %OF TOL. % of Spread = NO VARIATION * % of Tol.0000 Total 0 0 0 0 0 0 Mean #DIV/0! #DIV/0! 0 #DIV/0! #DIV/0! 0 Sigma #DIV/0! #DIV/0! = Xbar of A #DIV/0! =Xbar of B 6-Sigma #DIV/0! Within part variation Reproducibility . Range Operator B: 1 0. Gage R&R Short Form Study (2 time / 2 Operators x 5 parts) Instructions: 1) Type in shaded areas only. 5) Analyze the results to determine variability due to both Repeatability and Reproducibility.

2) If using coded data. Record results below. 3) This spreadsheet is set up for either a 5-part or 10-part study. (See table below) . Tolerance" and "Operator Names" MUST be filled in for the form to work properly!! Gage Name: Part No. be sure to write in the "Total Eng. Tolerance" in coded form. Tolerance: Date: Instructions for data collection: 1) Select 10 parts at random and number them 1 through 10.574 * #VALUE! = #VALUE! = Range Upper Control Limit Note: D4 is based on the number of Replications. two or three times each.: Operator B: Zero Equals: Characteristic: Operator C: Unit of Measure: Specification: Area: Total Eng. Operator A: 0 Operator B: 0 Operator C: Sample Replications Sample Replications Sample Replications Number 1 2 3 R Number 1 2 3 R Number 1 2 3 R 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 Totals Totals Totals Means Means Means Xbar1 Xbar2 Xbar3 RbarA Xbar1 Xbar2 Xbar3 RbarB Xbar1 Xbar2 Xbar3 RbarC XbarA = Xbar1 + Xbar2 + Xbar3 XbarB = Xbar1 + Xbar2 + Xbar3 XbarC = Xbar1 + Xbar2 + Xbar3 Replications Replications Replications XbarA = XbarB = XbarC = Test for Statistical Control of Ranges Rbar1 = RbarA + RbarB + RbarC = #VALUE! = #VALUE! Operators 2 UCLR = D4 * Rbar1 = 2. Gage R&R Long Form Study Instructions for this form: 1) Type only in the shaded blocks. 3) Analyze the results to determine variability due to both Repeatability and Reproducibility.: Part Name: Operator A: Graduations: Operation No.: Performed By: Gage No. Do not use for any other quantity!! 4) "Total Eng. (5 parts may be used if necessary) 2) Have two or three operators measure each part independently.

000000 Note: d2* is based on the number of Operators.693 = #VALUE! Note: d2 is based on the number of Replications.000000 = #VALUE! Range of Observations Within Each Trial Operator 1st trial 2nd Trial 3rd Trial TOTAL CAUTION: Percent Process Tolerance value is only valid for 5-part or 10-part studies.* See special Supplier Note below SMV = SOV2 + SGV2 = 0.15 * SGV = #VALUE! = #VALUE! Eng.15 * SOV = 0.00000 0.00000 B 0.{(Repeatability)2 / (No.00000 RbarCV (Sum/No.00000 0.15 * SGV #VALUE! Percent of Engineering Tolerance Consumed by the Gage: 100 * 5.000000 . trials)} = #VALUE! 100 * 5. Enter the Tolerance 0. Gage R&R Long Form Study Analysis Repeatability (Gage Variation) SGV = Rbar1 / d2 = #VALUE! / 1.XbarSmallest of ABC = 0.15 * SMV * SPECIAL SUPPLIER NOTE: Supplier needs to enter "Product Sigma" into HS Process = #VALUE! = #VALUE! Certification Database when creating a new Gage File for any HS defined KPCs/TKCs.078 / 0.00000 Sum 0.00000 0.906 = 0.000000 Reproducibility (Between Operator Variation) Rbar2 = XbarLargest of ABC .000000 = #DIV/0! Tolerance 0.00000 0. (See table below) Repeatability = 5.15/d2*)}2 .000000 Combined Reproducibility and Repeatability (Measurement System) PRODUCT SIGMA . 2) Percent of Process Tolerance (Combined Variability) consumed by measurement system: R&R = (Repeatability)2 + (Reproducibility)2 = #VALUE! Percent Process Tolerance (Combined Variability) = (R&R)/(6/d 2)*RbarCV = #VALUE! * 3.906 Percent of Engineering Tolerance consumed by Operator Variation: Reproducibility = {(Rbar2) X (5.000000 = 0.00000 0. (See table) Number of parts = 0 Number of trials = 0 d2 * = 1.000000 SOV = Rbar2 / d2* = 0.000000 / 1.00000 C 0. parts X No.000000 Product Sigma into the database field entitled "Gage RR Std Deviation". 0. A 0.000000 + #VALUE! = #VALUE! 1) Percent of Engineering Tolerance consumed by measurement system: 100 * 5. Trials) 0 .00000 0. Tolerance 0.

temperature.) that could influence the study results.128 1.e.078 Study Observation INSTRUCTIONS: Please record any significant observations. gage readability. Tolerance = (Gage R&R / Total Eng.268 1. Gage R&R Long Form Study Evaluation Guideline 1) GAGE CAPABILITY (GC) FOR PRODUCT ACCEPTANCE (% of Engineering Tolerance) GC as a % of Eng. ability to easily hold gage and/or part. difiiculties in using the measurement system (i.414 3 2. environmental factors (i.. n D4 d2 d2* 2 3. obtaining readings.e.574 1. Tolerance Range) * 100 = #VALUE! * SPECIAL SUPPLIER NOTE: Supplier needs to enter "Product Sigma" into HS Process Certification Database when creating a new Gage File for any HS defined KPCs/TKCs.693 1. vibration. Enter the Product Sigma into the database field entitled "Gage RR Std Deviation". lighting..906 5 2. distractions. etc.15 x Sigma CV) * 100 = #VALUE! LEGEND ACCEPTABLE MARGINAL UNACCEPTABLE Table of Factors used in calculations. such as Operator/Inspector methodical differences. . etc.). 2) GAGE CAPABILITY FOR CONTROL CHART PURPOSES (% of Process Tolerance) % of Process Tolerance = (R&R / 5.326 10 3.

1 = "Good" Assessor 100% 100% 90% Assessor A1 A2 E B1 B2 A 90% 90% 80% Assessor A Expert Assessor B B 80% Part 80% 70% Obs. I = 95% confidence bound.) Obs. 1 Obs. 2 E (opt. 1 Obs. Facility/Location: Gage Capability Attribute Study . 2 70% 1 60% 60% 1 2 Conclusions: 60% 50% Conclusions: 50% 3 50% 40% 40% 4 40% 30% 30% 5 30% 20% 6 20% 20% 7 10% 10% 10% 8 0% 0% 0% 9 10 x = each assessor's average. 11 12 Part 1 Part 2 Part 3 Part 4 Part 5 13 1 1 1 1 1 14 15 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 16 17 Part 6 Part 7 Part 8 Part 9 Part 10 18 1 1 1 1 1 19 20 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 21 22 Part 11 Part 12 Part 13 Part 14 Part 15 23 1 1 1 1 1 24 25 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 26 27 Part 16 Part 17 Part 18 Part 19 Part 20 28 1 1 1 1 1 29 30 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 31 32 Part 21 Part 22 Part 23 Part 24 Part 25 33 1 1 1 1 1 34 35 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 36 37 Part 26 Part 27 Part 28 Part 29 Part 30 38 1 1 1 1 1 39 40 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 41 42 Part 31 Part 32 Part 33 Part 34 Part 35 43 1 1 1 1 1 44 45 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 46 47 Part 36 Part 37 Part 38 Part 39 Part 40 48 1 1 1 1 1 49 50 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 Part 41 Part 42 Part 43 Part 44 Part 45 1 1 1 1 1 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 Part 46 Part 47 Part 48 Part 49 Part 50 1 1 1 1 1 0 0 0 0 0 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 A1 A2 E B1 B2 . 2 (Opt.Agreement between Assessors (AbA) Binary Study KPI / O: Key characteristic: Inspection method: Date of study: Study manager: Study manager: % a g r e e m e n t w ith th e m s e lv e s Comparison of performance Within Assessor Between Assessor Assessor / Expert % a g r e e m e n t b e tw e e n th e m % a gr e e m e nt w ith e x pe r t A1=A2 0 out of 0 or Consistency Agreement Agreement Within assessor consistency B1=B2 0 " 0 " A=B 0 " 0 " Between assessor agreement A=E 0 " 0 " Agreement with expert B=E 0 " 0 " 100% 0 = "Bad".) 70% Obs.

PFMEA Master & Proces Note: This tab may be unlocked to add additional line items. plea For instructions.Design Failure Mode and Effects Analysis (DFMEA This document contains no technical data subject to the EAR or the ITAR Supplier Name: Part #: Part Name: Dwg Revision: Note: Color code between Process Flow. slide cursor over col Potential Failure Line Component & Function Requirements Mode 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 48 49 50 .

dd additional line items. PFMEA Master & Process Control Plan are guidance to define link between documents.alysis (DFMEA) Worksheet R or the ITAR 0 0 0 0 Flow. For instructions to name and save the file. please ensure to copy an existing row to ensure formulas remain functional. slide cursor over this c Classification Occurrence Severity Potential Effect(s) of Potential Cause(s) of Failure Failure . slide cursor over column headings. tions.

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nd save the file. slide cursor over this cell. Detection Current Process Controls Current Process Controls RPN SD (Prevention) (Detection) 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 0 0 0 0 0 0 0 0 0 0 . DFMEA Team: Team Leader: DFMEA Date: (Original) (Revised) - ween documents. mulas remain functional.

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

- Recommended Actions and Predicted Risk Occurrence Detection Severity RPN SO SD Recommended Action 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 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 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 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 0 0 0 0 0 0 .

Largest RPN Value 0 Optional .For B Action Price Tag Champion SO Non-recurring Cost Recurring Cost (Approval Authority) 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

For Business Case Action Results Achieved Occurrence Responsibility and Severity Target Completion Action Taken Results Date . Largest SD Value 0 Largest SO Value Optional .

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0 d Detection RPN 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

Note: Color code between Process Flow. PFMEA Master & Process Control Plan are guidance to define link between docu Note: This tab may be unlocked to add additional line items. Name Process Step . # Op. Rework Scrap (KC's) Op. please ensure to copy an existing row to ensure formulas rem PROCESS FLOW DIAGRAM Part Name: 0 Dwg Rev: Part #: 0 Process Flow Rev: Prepared by: Classification Op. Move Store Insp.

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ine link between documents. ensure formulas remain functional. AM 0 Significant Product Significant Process Characteristic (Output) Characteristic (Input) .

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plea For instructions. PFMEA Master & Proces Note: This tab may be unlocked to add additional line items.Process Failure Mode and Effects Analysis (PFME This document contains no technical data subject to the EAR or the ITAR Supplier Name: Part #: Part Name: Dwg Revision: Note: Color code between Process Flow. & Process Potential Failure Line Requirements Name Mode 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 . slide cursor over col Process Step No.

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 .

slide cursor over this c Classification Occurrence Severity Potential Effect(s) of Potential Cause(s) of Failure Failure . dd additional line items. please ensure to copy an existing row to ensure formulas remain functional.nalysis (PFMEA) Worksheet R or the ITAR 0 0 0 0 Flow. For instructions to name and save the file. tions. PFMEA Master & Process Control Plan are guidance to define link between documents. slide cursor over column headings.

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mulas remain functional. PFMEA Team: Team Leader: PFMEA Date: (Original) (Revised) - ween documents. nd save the file. Detection Current Process Controls Current Process Controls RPN SD (Prevention) (Detection) 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 0 0 0 0 0 0 0 0 0 0 . slide cursor over this cell.

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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

- Recommended Actions and Predicted Risk Occurrence Detection Severity RPN SO SD Recommended Action 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 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 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 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 0 0 0 0 0 0 .

For B Action Price Tag Champion SO Non-recurring Cost Recurring Cost (Approval Authority) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . Largest RPN Value 0 Optional .

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 .

For Business Case Action Results Achieved Occurrence Responsibility and Severity Target Completion Action Taken Results Date . Largest SD Value 0 Largest SO Value Optional .

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0 d Detection RPN 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

does 8 Major disruption function not affect safe vehicle operation) Degradation of primary function (vehicle Significant Essential 7 operable.FMEA RISK TABLES SEVERITY RISK TABLE Category Criteria: Severity of Effect Category Rank (Product) (Effect on Product) (Process) Potential failure mode affects safe vehicle operation and/or involves noncompliance with 10 Safety and/or government regulation without warning Safety and/or regulatory regulatory compliance Potential failure mode affects safe vehicle compliance operation and/or involves noncompliance with 9 government regulation with warning Primary Loss of primary function (vehicle inoperable. cannot detect or is 10 Almost impossible opportunity not analyzed . Defect noticed by 2 disruption discriminating customers (< 25%) No effect No discernible effect 1 No effect DETECTION RISK TABLE Opportunity for PFMEA Criteria: Likelihood of Rank Detection Likelihood of detection by process control Detection No detection No current process control. but at reduced level of performance) disruption Secondary Loss of secondary function (vehicle operable. but comfort / convenience functions at 5 reduced level of performance) Appearance or audible noise. vehicle operable. vehicle operable. Defect noticed by most 4 customers (> 75%) Rework in Appearance or audible noise. vehicle operable. Minor item does not conform. station Annoyance item does not conform. item does not conform. Defect noticed by many 3 customers (50%) Appearance or audible noise. but 6 function comfort / convenience functions inoperable) Rework out of Degradation of secondary function (vehicle station Convenient operable.

machine design or part design. etc) Failure Mode or Error (cause) detection in-station by operator through the use of variable gauging. manual torque check/clicker wrench. buzzer.g.Not likely to detect Failure Mode and/or error (cause) is not easily 9 Very remote at any stage detected (e.) Gauging performed on setup and first-piece check (for setup causes only) Failure Mode detection post-processing by Problem detection automated controls that will detect discrepant part 4 Moderately high post processing and lock part to prevent further processing Failure Mode detection in-station by automated Problem detection controls that will detect discrepant part and 3 High at source automatically lock part in station to prevent further processing Error detection Error (cause) detection in station by automated and/or Problem controls that will detect error and prevent 2 Very high prevention discrepant part from being made Error (cause) prevention as a result of fixture Detection not design. . error Discrepant parts cannot be made because item 1 Almost certain prevention has been error-proofed by process/product design. etc. etc) Failure Mode detection post-processing by operator through the use of variable gauging or Problem detection in-station by operator through use of attribute 6 Low post processing gauging (go/no go. applicable. random audits) Problem detection Failure Mode detection post-processing by 8 Remote post processing operator through visual/tactile/audible means Failure Mode detection in station by operator through visual/tactile/audible means or post- Problem detection processing through use of attribute gauging 7 Very low at source (go/no go. Problem detection or by automated controls in-station that will detect 5 Moderate at source discrepant part and notify operator (light. manual torque check/clicker wrench.

TABLE OCCURRENCE Criteria: Severity of Effect Likelihood of Failure Time-based Scale (Effect on Process) May endanger operator (machine or assembly) Very High 1 occurrence / shift without warning Failure is almost inevitable High May endanger operator (machine or assembly) Failures occur almost 1 occurrence / day with warning as often as not 100% of product may have to be scrapped. Deviation from primary process. Failures occur 1 per week decreased line speed or added manpower often 100% of production run may have to be reworked Moderate High 1 per 2 weeks off line and accepted Frequent failures A portion of the production run may have to be Moderate 1 per month reworked off line and accepted Occasional failures 100% of production run may have to be reworked Moderate Low 1 per quarter in station before it is processed Infrequent failures A portion of the production run may have to be Low 1 per half-year reworked in station before it is processed Relatively few failures Low Slight inconvenience to process. operation or Failures are few and far 1 per year operator between Very Low Failure is eliminated No discernible effect <1 per year through prevention controls . Line High 1 per 2-3 days shutdown or stop ship Repeated failures A portion of the production rue may have to be High scrapped.

5 per thousand Cpk » 1.83 7 1 in 100 2 per thousand Cpk » 1.33 9 1 in 20 20 per thousand Cpk » 0.PFMEA Event-based Scale Rank (incidents per 1000 items / vehicles) ³ 100 per thousand Cpk < 0.1 per thousand Cpk » 1.67 8 1 in 50 10 per thousand Cpk » 0.00 6 1 in 500 0.001 per thousand Cpk » 2.00 2 1 in 1 000 000 Failure is eliminated Cpk > 2.17 5 1 in 2 000 0.00 1 through preventive control .CURRENCE RISK TABLE Criteria: Occurrence of cause .01 per thousand Cpk » 1.33 4 1 in 10 000 0.33 10 >/= 1 in 10 50 per thousand Cpk » 0.67 3 1 in 100 000 £ 0.

PRODUCT . please ensure to copy an existing row to ensure formulas remain fu PRO PROTOTYPE PRE-LAUNCH PRODUCTION CONTROL PLAN NUMBER PART NUMBER 0 PART NAME / DESCRIPTION 0 DRAWING NUMBER SUPPLIER/PLANT SITE CHARACTERISTICS PART / PROCESS NAME MACHINE.Note: Color code between Process Flow. PFMEA Master & Process Control Plan are guidance to define link between documen Note: This tab may be unlocked to add additional line items. DEVICE PROCESS / OPERATION JIG. TOOLS NUMBER DESCRIPTION FOR MFG NO.

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to define link between documents. PROCESS CONTROL PLAN CUSTOMER ENGINEERING DATE ORIGINAL APPROVAL/DATE (if required) CUSTOMER QUALITY DATE REVISED APPROVAL/DATE (if required) OTHER APPROVAL/DATE PREPARED BY (if required) OTHER APPROVAL/DATE APPROVED BY (if required) DRAWING REV 0 SUPPLIER KEY CONTACT SUPPLIER CODE 0 KEY CONTACT PHONE / EMAIL HARACTERISTICS METHOD CLASSIFICATION PRODUCT / EVALUATION / PROCESS PROCESS MEASUREMENT SPECIFICATION TECHNIQUE TOLERANCE . row to ensure formulas remain functional.

.

.ER ENGINEERING /DATE (if required) STOMER QUALITY /DATE (if required) APPROVAL/DATE (if required) APPROVAL/DATE (if required) ER KEY CONTACT T PHONE / EMAIL METHOD SAMPLE REACTION CONTROL PLAN METHOD SIZE FREQ.

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UPPAP SUPPLIER EVIDENCE PACKAGE
Record of Revisions
REVISION NATURE OF CHANGE AUTHOR OF CHANGE

Added the following Worksheets:
Record of Revisions Tab
Appendix 1) Change Control Form 2
Revision A Appendix 2) Capability Calculator
Appendix 3) Gage R&R Short Form Peter E. Teti
April 2012
Appendix 4) Gage R&R Short Form with 2 replications
Appendix 5) Gage R&R Long Form
Appendix 6) Gage R&R Attribute Study Instruction Sheet
Appendix 7) Gage R&R Attribute Study Form
All Appendexes hyperlinked from Cover & Index (Tab B)

1) Revised DFMEA and PFMEA worksheets to bring up to
J1739 standard
2) Added Appendix 8, "FMEA Risk Tables" which were derived
from the J1739 standard
Revision B 3) Modified Tab 9, Initial Process Studies. Added Column called Peter E. Teti
December 2012 "Cpk Results" and provided conditional formatting for the
column called "Cpk Action"
4) Modified Tab 10- MSA with conditional formatting in column
labelled "Gage R&R Result"
5) Revised Tab 7, Process Control Plan, with a new template
based on the AIAG format.
1) Revised DFMEA and PFMEA worksheets by adding "SO"
Peter E. Teti
Revision C columns for "Severity*Occurrence" risk calculation.
July 2013 2) Revised nomenclature for DFMEA & PFMEA title blocks to go
Peter E. Teti
from "FMEA" to specifically DFMEA and PFMEA.
Revision D Brian Murphy
March 2016 Alignment to ASQR-09.2 Revision 1, all Tab Elements updated.
Revision E Appx J re-formated, conditional formating added to some field Brian Murphy
May 2016 thoughout workbook, fixed document attachment issue.

TITLE DIVISION

Technical Fellow-Product
Pratt & Whitney
Quality

Technical Fellow-Product
Pratt & Whitney
Quality

Technical Fellow-Product
Pratt & Whitney
Quality
Technical Fellow-Product
Pratt & Whitney
Quality
UPPAP Council Lead UTC

UPPAP Council Lead UTC