Professional Documents
Culture Documents
1.6 2/28/2014 Andrea Krueger Added Revisions History Tab, Updated PSW to unclude IPS specific information for Level 1, Added
PRINT NOTES - Performance Tests Tab and updated PRINT NOTES - Welding with attaching copies
of WPS/PQR; finished update of tab footers
Updated PPAP Requirements tab with N/R information and * specific reqs. Removed buyer Number
from PSW; Added conditional formatting to the dimensional tab, split the paint tab into 2 tabs (paint
and plating) & Appearance Approval Tab update, added "Format for example only; Supplier created
1.7 1/31/2015 Andrea Krueger templates may be used" for any example template in the workbook
Added Section J labeling tab and PPAP requirements; Updates to PSW materials, reporting, paint
worksheet added surface profile, weld worksheet added piece 1-3, replaced ratings matrix for S,O,D,
added criticality matrix, added QC-112 PPAP check list, added QC-116 COTS exceptions form,
Andrea Krueger / added QC-112 to PPAP requirements matrix and PSW check boxes, capability worksheet replaced
1.8 4/30/2017 Scott Ball with web link, DFMEA & PFMEA worksheets replaced.
Revised the PSW citation to D.32 for the SSG. Removed QC-116 COTS exception form. Added C of
C Template. Revised QC-112 to include castings section and heading information automatic fill.
1.9 2/12/2018 Scott Ball Revised the Detection ratings scale.
Revised the QC-112 check list; COTS, Armor. Revised the Print Notes- Plating worksheet, C of C
2.0 4/8/2019 Scott Ball changed to Excel format. Revised Print Notes- Paint worksheet to include ARL # and cyclical testing
PSW- included QC-112 in description for level 3 requirement, C of C Template: added supplier PN,
Scott Ball / Andrea added "evidence of commerciality…", added tab for UID TRACEABILITY LABEL, Added to the paint
2.1 8/4/2020 Krueger and plating worksheet, revised QC-112 checklist C of C section, updated Oshkosh Logo
Oshkosh Corporation Classification - Restricted #_x000D_
Revision 2.1
October 1, 2020
PPAP INTRODUCTION
PPAP packages are expected to be received by Oshkosh Corporation by the date assigned by Oshkosh Corporation Designee. If for any
reason you cannot meet this date, contact Oshkosh Corporation Designee for resolution.
It is the policy of Oshkosh Corporation to approve initial samples of supplier provided parts before receiving production orders of those parts
Oshkosh has developed the PPAP PROCESS to facilitate this requirement.
The Default PPAP is Level 2, unless otherwise required by the Oshkosh Segment Quality Representative
PPAP requirements apply to the following parts:
1) Initial submission
2) Engineering Change(s)
3) Tooling: Transfer, Replacement, Refurbishment, or additional
4) Correction of Discrepancy
5) Production Break to Oshkosh Corporation > 1 year
6) Change to Optional Construction or Material
7) Sub-Supplier or Material Source Change
8) Change in Part Processing
9) Parts produced at Additional Location
10) Other - please specify
Please reference the Oshkosh Corporation Global Supplier Quality Manual for more detail on PPAP
requirements. The Manual can be retrieved on the http://osn.oshkoshcorp.com/ website.
Oshkosh Corporation
PPAP Part Submission Requirements
Part Number: PART NUMBER Purchase Order No.
Revision Level: ERL DATE Part Description: PART NAME
Supplier Name: SUPPLIER NAME Reason for Request: ALL PPAP CRITERIA
Supplier Number: 101112 OSK Program: MODEL / VEHICLE MUST CONFORM TO
Date Issued: Submission Due Date: Oshkosh Corporation Customer Specifics
defined in the Global Supplier Quality Manual
Submission Level
PPAP Submission Requirements and Detail Description 1 2 3 4
1.) Part Submission Warrant (PSW) S S S S
2.) Dimensional Results (Sub-Components Required - Refer to OSK-P2000 Production Part Approval Process (Sec 5.6) N/R S S S
3.) Design Records (Bubble Print) N/R S S S
4.) PPAP Samples - first production order / upon request prior to production order N/R S S S
5.) Print Notes: (Attach copy of Raw Material Certification / Performance Test Report / Surface Finish, Paint Process, Welding
Documentation such as WPS/PQRs/Welder Certs) * S S *
6.) Supplier Change Request (OSK-F1000) - if applicable S S S S
7.) Design Failure Modes effects Analysis (DFMEA) - if supplier is design responsible N/R N/R S N/R
8.) Process Flow Diagram (PFD) N/R N/R S N/R
9.) Process Failure Modes Effects Analysis (PFMEA) N/R N/R S N/R
10.) Initial Process Capability - for major / critical characteristics - if applicable N/R N/R S N/R
11.) Measurement System Analysis (MSA) - for major / critical characteristics - if applicable N/R N/R S N/R
12.) Process Control Plan N/R N/R S N/R
13.) Appearance Approval Report (AAR) - if applicable N/R N/R S N/R
14.) Checking Aids (Fixture, gage, template, etc) - if applicable N/R N/R S N/R
15.) Records of Compliance with Customer Specific Requirements - if applicable N/R N/R S N/R
16.) Photo Documentation (Master Sample of PPAP parts & Section J-Labeling) S S S N/R
17.) Tooling Photo Documentation - if applicable N/R S S N/R
18.) QC-112 PPAP Check List N/R N/R S N/R
Additional Submission Instructions below:
Send identified sample(s), such as, Piece#1, Piece#2, Piece#3, etc to Oshkosh Corporation with appropriate label.
Please complete and attach this page on the outside of each package in plain view of a fork lift/material
handler/operator. Put the Packing slip pocket near the label.
In the event parts are “Loose” shipped, a label should be placed on each part. This would also apply to parts
laying on pallets. Label on a painted part must be wire tied or attached in a way such that the painted surface
is protected from label adhesion.
Purchased Order#:
Part Number:
Revision Level:
Supplier Name:
Supplier Number:
ADDRESS
Street Address Buyer
MATERIALS REPORTING
Compliant to requirements stated in the Suppliers Standards Guide (Section D.32) referencing Hazardous Materials.
Yes No
REASON FOR SUBMISSION (Check at least one)
Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Production Break to Oshkosh Corporation > 1 year Other - please specify
Level 4
(Check items that have been submitted within this PPAP Submission)
I have noted on this part submission warrant any deviation from the associated design record and/or any areas of non-compliance to the Oshkosh Corporation requirements. If
Yes, Explain _____________________________________________________________________
_______________________________________________________________________________________________________________
Supplier Name:
Supplier Number:
Part Description:
Supplier's Part Number:
The following are the minimum PPAP elements that must be submitted with a COTS item.
I certify that the items / materials referenced above are commercially available.
I certify that the above mentioned items/materials meet the purchase order requirements and referenced drawing specifications and
standards. I also certify I am an authorized supplier representative.
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
*Commercial Off the Shelf (COTS) - (If Applicable on Purchased Part Level) Y N N/A Comments
Is this component Commercial Off the Shelf (commercially available to the general public, unaltered, and under
1 the manufacturers’ EXACT part number) as defined in the Defense Segment Addendum, Section 14?
If the answer to question 1 is yes, are the minimum PPAP elements for a COTS part (including a catalog page or
equivalent, verbatim to address all OSK specifications) provided in accordance to the COTS section in the Defense
1A Segment Addendum, Section 14, and in accordance to the OSK Certificate of Conformance form?
Is this component COTS plus (commercially available but with additional performance / print requirements) as
2 defined in the Defense Segment Addendum, Section 14
If the answer to question 2 is yes, have you provided objective evidence that the part meets all of the OSK print
2A requirement? (see Defense Segment Addendum, Section 14)
2.2.18 Does the revision level for the drawing submitted match the Purchase Order?
2.2.18 Is the Materials Report Section in compliance with Suppliers Standards Guide (Section D.32)?
2.2.18 Are the reason(s) for PPAP submittal accurate AND checked?
2.2.18 Is the correct Submission level checked AND applicable elements checked?
2.2.9 Dimensional Results / Print Notes Y N N/A Comments
2.2.9 Are the dimensional results, dated-signed and relatively current?
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
2.2.9 Are the MIN / MAX spec limits on the ISIR correct according to the TOLERANCE limits on the print?
2.2.9 Are proper GAGE TYPES used for the specified tolerance (adequate discrimination)?
2.2.9 Are proper GAGE TYPES used for the application (calipers / tape measures have limited use)?
2.2.9 Are multiple dimensions ALL listed and ALL verified (example 2x's, 6x's, etc.)?
2.2.9 Are MSA / GRR / Capability Studies provided for Critical Characteristics?
2.2.9 For multi-cavity tooling, at least 1 piece per cavity must have a complete layout
2.2.9 Print Notes Y N N/A Comments
2.2.9 Are all print notes addressed?
Are there requirements in the Notes for which Certifications are needed? (Painting, Plating, Welding, material,
2.2.9
traceability, performance testing)
2.2.9 Are three pieces verified and the results recorded for each print note as required for Level 3 PPAP?
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
2.2.1 Is the drawing or design record at the proper engineering/revision level and does it matches the P.O.?
2.2.1 Are all dimensions including notes (weld symbols, etc.) ballooned on the drawing?
2.2.2 & Authorized Engineering Change Docs (RCM (Reliance Change Management)/Customer Engineering
2.2.3 approval Y N N/A Comments
Is there an approved Deviation Request, submitted to RCM (Reliance Change Management) system, included for
2.2.3
all Dimensions, Notes, and Print Discrepancies that do not meet requirements?
2.2.2 &
Is the approved Change Request valid for the order produced?
2.2.3
2.2.4 DFMEA Y N N/A Comments
If the supplier is design responsible: Is the DFMEA is included within the PPAP OR is there a record indicating it
2.2.4
was reviewed & approved by OSK?
2.2.4 Does the print indicate that the component is "Source Control" or "Vendor Item Control"? (no = NA)
2.2.4 Are Significant Characteristics (Special/ Critical) identified and captured within the DFMEA (no= NA)?
2.2.4 If Oshkosh is design responsible: Are there SC / CC's present on the print (no = NA)?
If Oshkosh is design responsible and the part is manufactured by OSK: Are the sub-component level PPAP's
2.2.4
present with submittal (no = NA)?
2.2.5 Process Flow Diagram(s) Y N N/A Comments
Does the PPAP documentation cite specific print note requirements (associated with product or process) in Flow /
2.2.5
PFMEA/ Control Plan (For Example Mil-STD-130 Part Marking ID)?
2.2.5 Does the Flow Diagram reflect the entire process e.g. Receiving, outside processing?
2.2.5 Are the process steps for the Process Flow, PFMEA and Control Plan aligned?
2.2.6 PFMEA Y N N/A Comments
2.2.6 Has the PFMEA been constructed utilizing the OSK ranking worksheet for Severity and Occurrences?
Are there SC / CC identified by the Supplier? "NO" = N/A (refer to Criticality Matrix in Global Supplier Quality
2.2.6
Manual)
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
In cases where SC/CC have been identified, does the supplier have SPC or 100% inspection for them noted in the
2.2.6
"Control Method" column?
2.2.6 Are Detection values correct for Visual Inspection per AIAG (Minimum 7 or 8)?
2.2.7 Are Product and Process Characteristics properly identified (in the correct columns) per the AIAG definitions?
2.2.7 Does the Control Plan cover all activities from receiving inspection to shipment?
2.2.7 Are all Special Product/Process Characteristics included in the Control Plan?
2.2.7 Are Control Method tools such as SPC or 100% inspection for the Special Characteristics defined?
Does the PPAP documentation cite specific print note requirements (associated with product or process) in Flow /
2.2.7
PFMEA/ Control Plan (For Example Mil-STD-130 Part Marking ID)?
2.2.11 Initial Process Studies Y N N/A Comments
If there are SC/CC identified (on print or supplier process): Does the supplier meet Cpk of 1.33 for Significant
2.2.11
Characteristics and/or Cpk of 1.67 for Critical Characteristics?
If there are SC/CC identified (on print or supplier process) and the supplier conducts 100% inspection instead of
2.2.7
Capability Studies, is inspecton included on the Control Plan?
Were the initial process studies conducted using the required number of samples and using production processing,
2.2.7
gauging and materials?
2.2.8 MSA Y N N/A Comments
2.2.8 Are there SC/CC's identified (on print or supplier process) and MSA is included in PPAP?
Has the MSA been constructed using the Defense Segment MSA Instruction Guide (located:
2.2.8
https://osn.oshkoshcorp.com)?
Was the MSA Report / Checklist used to ensure completeness (included within the Defense Segment MSA
2.2.8
Instruction Guide)?
2.2.8 Does the PPAP package contain a photo of the measurement tool?
2.2.13 Appearance Approval Y N N/A Comments
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
2.2.16 Has the supplier provided preventive maintenance / calibration records for the checking aids?
2.2.16 Do all aspects of the checking aids agree with part dimension requirements?
2.2.10 Material / Performance Testing Y N N/A Comments
2.2.10 Are material certifications included for all requirements specified on the print?
Are material certification(s) provided (where no specification is given) to establish a base-line of product
2.2.10
acceptability?
2.2.10 Are material certification(s) dated relatively recent (within 12 months)?
2.2.10 Are material certification(s) included for hardware called-out on the print?
2.2.12 Does the test report indicate testing was done externally by a 3rd party?
Do the Material or Performance Tests results meet the requirements outlined in section 13 of the GSQM Defense
2.2.12
Addendum?
2.2.14 Sample Production Parts Y N N/A Comments
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
2.2.14 Are the PPAP parts identified per section 13 of the Defense Addendum prior to shipment?
2.2.15 Master Sample (photo) Y N N/A Comments
2.2.15 Do they capture paint / no paint zones?
2.2.15 Do they capture the part marking ID and it is correct per print requirements?
2 Has circuit testing been completed? Spec 400 sec 5.6 (or applicable standards)
5 Are continuity tests conducted per spec 400 (or applicable standards) AND identified within the Control Plan?
2 Do paint worksheets verify conformance to pre-treatment, coating, mil thickness, adhesion, permeability for 3
pieces?
3* Do paint or plating worksheets verify conformance to the finish drawing number and the revision level
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
6 Are oven cure times & temperatures recorded?
7 Are test results included for cyclical testing (GMW 14872) if JLTV Finish print (12593834) is referenced?
8 CARC Paint Certification: Is the ARL (Army Research Lab) certification with corresponding the batch number if
CARC paint is required?
Weld Y N N/A Comments
1 Are all weld lengths, sizes, types & locations cited on the ballooned drawing?
2 Are the WPS AND PQR's #'s referenced on the PPAP worksheet?
3 Are the WPS AND PQR's #'s INCLUDED in the PPAP submittal?
4 Are the WPS and PQR authorized by a CWI (or equivalent authority)?
6 If WPS not required per AWS (for example), are appropriate weld documentation and verification methods
included?
Castings
Either questions 1-3 OR 4-6 will apply depending on the casting standards stated on drawing Y N N/A Comments
1 Are personnel performing radiographic inspection reports certified in accordance with ASNT (American Society for
Non-Destructive Testing) Level 2?
2 Are the ASNT (American Society for Non-Destructive Testing) certified radiographic procedures being approved by
a level 3 Technician?
3 Are certifications submitted within the PPAP for personnel verifying compliance to ASNT (American Society for
Non-Destructive Testing)?
4 Are personnel performing radiographic inspections certified in accordance with NAS 410 Level 2?
5 Are the NAS 410 certified radiographic procedures being approved by a level 3 Technician?
6 Are certifications submitted within the PPAP for personnel verifying compliance to NAS 410?
7 Is the Inspection laboratory accredited (e.g. A2LA, ISO17025 for radiographic inspection per ASTM E1742 (film) or
E1255 (digital)?
9 Does the report reference the correct inspection standards as stated within AMS 2175A (ASTM E155/E2422 for
aluminum, ASTM E186/E446 for steel, iron)
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
10 Does the report specify casting grade and does it match drawing requirements?
11 Does the report specify casting class and does it match drawing requirements?
12 Does the report include melt numbers, heat lot numbers or date codes?
13 Do radiographic images show that Image Quality Indicator (IQI) placement is compliant to 2-2T per ASTM E1255
(digital) or ASTM E1742 (film)?
14 Do the print notes, PFMEA and/or Control Plan document address gate, riser and parting line projections comply
with AMS2175A table 3 (page 11 of 20)?
15 Does the control plan reflect radiographic sampling frequency in accordance with the print note / Global Supplier
Quality Manual?
16 Does the control plan reflect radiographic sampling for all mold cavities in accordance with the print note / Global
Supplier Quality Manual?
17 Is there evidence within the Control Plan that visual inspections were performed with ambient lighting that is not
less than 75 foot-candles (approximately a 60W incandescent bulb)?
18 Does the control plan specify that castings are 100% visually examined per AMS2175A, 4.3.1?
19 Is a written procedure listed within the Process Control Plan as to how to inspect the component IAW E1255 (digital
image), section A1.5.2 or E1742 (film image), section 6.1?
20* Is there measurement / photo evidence in the PPAP that the casting wall thickness / inner passges (if applicable)
have been measured as outlined in the Global Supplier Quality Manual- Defense Addendum (section 11)?
21* Does the control plan state that the casting wall thickness / inner passges (if applicable) will be measured semi-
annually as outlined in the Global Supplier Quality Manual- Defense Addendum (section 11)?
3 If traceability is required on the print, is it referenced in the PFD, PFMEA, and Control Plan, and identified as a CC?
4 If traceability is required on the print, is the appropriate label (i.e. Green Label vs UID) photographed, and is it
photographed in such a way that Oshkosh engineering can verify the snowflake data structure?
5 If part is welded, is the 48 hour weld hold process step included in the PFD, PFMEA, and Control Plan?
Requirements (CFAT)
Engineering Changes
Appearance Approval
Material Performance
Sample Production
Process Capability
Customer Specific
Results/Print Notes
Design Record
Checking Aids
Control Plan
DFMEA
PFMEA
Testing
Parts
MSA
Dimensional
2.2.18 2.2.9 2.2.1 2.2.2 2.2.4 2.2.5 2.2.6 2.2.7 2.2.11 2.2.8 2.2.13 2.2.16 2.2.10 2.2.12 2.2.14 2.2.15 2.2.17
Elements shaded green (above) indicate minimum submittal for interim approval
AIAG-PPAP PPAP Element PPAP Submission Comments
Section
6 If the part is welded, does the WPS, PQR, and Welder Qualifications meet the requirements of the Ground Combat
Vehicle Weld Code?
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
Comments
ART NUMBER
PART NAME
ERL DATE
F
Submission Comments
DIMENSIONAL RESULTS
DIMENSION / TOLERANCE SPECIFICATION / LIMITS GAGE QTY. ORGANIZATION MEASUREMENT RESULTS (DATA) NOT
ITEM OK
SPECIFICATION TYPE* TESTED Piece 1 Piece 2 Piece 3 OK
- + MIN MAX
PRINT NOTES
(ATTACH COPY OF RAW MATERIAL CERTIFICATION, SURFACE FINISH,
& PART IDENTIFICATION)
ORGANIZATION: SUPPLIER NAME PART NUMBER: PART NUMBER
SUPPLIER NUMBER: 101112 PART NAME: PART NAME
PRINT NOTES
(ATTACH COPY OF PERFORMANCE TESTS )
Prime Coat:
Blast / Surface Profile
Thickness*
Thickness (including blast profile)*
Permeability
Adhesion
Oven Cure Time (if used)
Ambient Cure Time (if used)
ASTM B117/
Salt Spray TTC-490
Defense Segment: Compliant to the requirements stated in the Suppliers Standards Guide (Section
(Circle) Yes / No Signed by:
D.32) referencing Hazardous Materials.
* Rejection will not be made based on coating thickness in excess of the maximum alone, but on a subsequent performance failure per MIL-DTL 53072 Sec 4.2.3.3.
Defense Segment: Compliant to the requirements stated in the Suppliers Standards Guide (Section D.32)
(Circle) Yes / No Signed by:
referencing Hazardous Materials.
RL
NOT
OK
PRINT NOTES
(ATTACH COPY OF WPS/PQR DOCUMENTATION)
NT NOTES
WPS/PQR DOCUMENTATION)
PART NUMBER
PART NAME
ERL DATE
NOT
OK
Criticality Matrix
10 <CC> Critical Characteristic
Must be addressed on Control Plan
with 100% inspection or 1.67 Cpk
9
8
<SC> Significant Characteristic
7
Must be addressed on Control Plan
Severity
Occurrence
ASSY
CUSTOMER EFFECT SEVERITY OF EFFECT ON PRODUCT RANK SEVERITY OF EFFECT ON PROCESS
EFFECT
Potential failure mode affects safe vehicle operation Hazardous
May endanger operator (machine or
and/or involves noncompliance with government 10 without
Failure to Meet Safety assembly) without warning. warning
regulation without warning.
and/or Regulatory
Requirements Potential failure mode affects safe vehicle operation
May endanger operator (machine or Hazardous
and/or involves noncompliance with government 9 with warning
assembly) with warning.
regulation with warning
Loss of primary function (vehicle / item inoperable, but 100% of production run may have to be Major
8 Disruption
does not affect safe operation). scrapped, line shutdown, or stop ship.
Loss or Degradation of A portion of the production run may have to
Primary Function Degradation of primary function (vehicle / item be scrapped, deviation from primary process Significant
7 Disruption
operable but at a reduced level of performance) including decreased line speed or added
manpower.
Loss of secondary function (vehicle / item operable,
100% of production run may have to be
but does not affect safe operation, but secondary 6
reworked off line and accepted.
Loss or Degradation of functions inoperable) Moderate
Secondary Function Degradation of secondary function (vehicle / item Disruption
A portion of the production run may have to
operable, but secondary functions operate at reduced 5
be reworked off line and accepted.
level of performance)
Condition impacting a tertiary function but vehicle
remains operable, appearance or audible noise, or 100% of production run may have to be
4
item does not conform and noticed by >75% of reworked in station before it is processed.
customers Minor
Condition impacting a tertiary function but vehicle Disruption
A portion of the production run may have to
Loss or Degradation of remains operable, appearance or audible noise, or
3 be reworked in station before it is
Tertiary Function item does not conform and noticed by ~50% of
processed.
customers
Condition impacting a tertiary function but vehicle
remains operable, appearance or audible noise, or Slight inconvenience to process, operation,
2 Annoyance
item does not conform and noticed by <25% of or operator.
customers
No effect No discernible effect 1 No discernible effect. None
OCCURRENCE OF
LIKELIHOOD OF OCCURRENCE OF CAUSE OCCURRENCE OF CAUSE
CAUSE
FAILURE FROM TESTING FOR PFMEA
FOR DFMEA
One occurrence
Very High Observed on over 50% of test assets. New technology/new design with no history.
per part/machine
Failure is inevitable with new design, new One occurrence
application, or change in duty cycle/operating per shift
conditions. *(>1 in 5)
One occurrence
Failure is likely with new design, new application,
High Observed on >25-50% of test assets. per day
or change in duty cycle/operating conditions.
*(1 in 5)
Failure is uncertain with new design, new One occurrence
application, or change in duty cycle/operating per week
conditions. *(1 in 25)
One occurrence
Frequent failures associated with similar designs
every 2 weeks
or in design simulation and testing.
*(1 in 50)
One occurrence
Occasional failures associated with similar
Moderate Observed on >12.5-25% of test assets. per month
designs or in design simulation and testing.
*(1 in 100)
One occurrence
Isolated Failures associated with similar design or
per 3 months
in design simulation and testing.
*(1 in 300)
Only isolated failures associated with almost One occurrence
Low Observed on up to 12.5% of test assets. identical design or in design simulation and per 6 months
testing. *(1 in 600)
No observed failures associated with almost One occurrence
identical design or in design simulation and per year
testing. *(1 in 1200)
Very Low No occurrences observed during testing.
Less than one occurrence per year
Failure is eliminated through preventive control.
*(<1 in 1200)
*Occurrence frequency for PFMEA should be calculated based upon yearly production volumes
(for example, if 1200 units are produced each year, one occurrence per month equals 1 in 100 units produced)
RANK
10
Failure Mode detection post-processing by operator through use of variable gauging or in-station
6 Problem Detection Post Processing
by operator through use of attribute gauging (go/no go, manual torque check/clicker wrench, etc.)
Failure Mode or Error (Cause) detection in-station by operator through use of variable gauging or
5 Problem Detection at Source by automated controls in-station that will detect discrepant part and notify operator (light, buzzer,
etc.). Gauging performed on setup and first-piece check (for set-up causes only).
Failure Mode detection post-processing by automated controls that will detect discrepant part and
4 Problem Detection Post Processing
lock part to prevent further processing.
Failure Mode detection in-station by automated controls that will detect discrepant part and
3 Problem Detection at Source
prevent automatically lock part in station to prevent further processing.
Error (Cause) detection in-station by automated controls that will detect error and prevent
2 Error Detection and/or Problem Prevention
discrepant part from being made.
Error (Cause) prevention as a result of fixture design, machine design or part design. Discrepant
1 Detection not applicable; Failure Prevention
parts cannot be made because item has been error-proofed by process/product design.
This scale was adapted from the AIAG FMEA Manual (4th Edition)
Current Current
Action Results
Occurrence
Responsibility
Detection
Design Design
Classification
Severity
Potential Potential Potential
Item / Recommended & Target
RPN
Requirements Failure Effect(s) Causes(s) Controls Controls Actions
Function Action(s) Completion
OCC
Mode of Failure of Failure
DET
SEV
Prevention Detection Date Taken & Effective
Date
RPN
PROCESS/INSPECTION FLOWCHART
(Format for example only; Supplier created templates may be used)
Legend:
Operation Transportation Inspection Delay Storage
Operation
Transportation
Inspection
Delay
Storage
Change History
Date Revision
Classification
Occurrence
Process Process Responsibility
Detection
Severity
Process Step / Potential Potential Potential
Recommended & Target
RPN
Function Requirements Failure Effect(s) Causes(s) Controls Controls Actions
Action(s) Completion
OCC
RPN
SEV
DET
Mode of Failure of Failure Prevention Detection Taken & Effective
Date
Date
CONTROL PLAN
(Format for example only; Supplier created templates may be used)
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
1/1/1996 1/1/1996
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
PART NUMBER
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
PART NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
101112
MACHINE, CHARACTERISTICS METHODS
PART/ PROCESS NAME/ SPECIAL
DEVICE PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
PROCESS OPERATION CHAR.
JIG, TOOLS CONTROL PLAN
NUMBER DESCRIPTION NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT
FOR MFG. SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
ERL DATE
PHOTO OR EXCERPT AS EVIDENCE THE SCANED MATRIX IS READABLE AND A LOG IS MAINTAINED FOR TRACEABILITY PURPOSES
Supplier is required to provide sample of SSG Section J compliant label(s) and document with Photo in PPAP workbook
Supplier is required to identify all Oshkosh Owned Tools & Fixtures and document with Photo in PPAP workbook
Click on the link below to access a template that will display control charts, histogram and Cp/Cpk results
Once the template has been populated you can copy and paste it onto this worksheet
http://asq.org/sixsigma/2008/05/process-capability-study-1500.html?shl=090025
ATTRIBUTE DATA
# XT a P'a After entering data, follow the directions on the tab marked
1 0.000 'Graph' to create the Gage Performance Curve
2 0.000
3 0.000
4 0.000
5 0.000
6 0.000
7 0.000
8 0.000
9 0.000
t Statistic
t = 31.3 IBI / R t0.025,19 = 2.093
=
=
Result
Reviewed
Title
Directions for Gage Performance Curve for Attribute Analytical Method Form
DATA TABLE
Reference
PART A-1 A-2 A-3 B-1 B-2 B-3 C-1 C-2 C-3 Reference Value Code
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
Risk Analysis
A * B Crosstabulation
B
Total
0 1
0 Count 0 0 0
Expected Count
A
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count
B * C Crosstabulation
C
Total
0 1
0 Count 0 0 0
Expected Count
B
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count
A * C Crosstabulation
C
Total
0 1
0 Count 0 0 0
Expected Count
A
1 Count 0 0 0
Expected Count
Count 0 0 0
Total
Expected Count
Kappa A B C
A -
B -
C -
DETERMINATION
AxB
AxC
BxC
PART NUMBER
Part Name Gage Number Appraiser B
PART NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
PART NUMBER
Part Name Gage Number Appraiser B
PART NAME
Characteristic Gage Type Appraiser C
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
Note: The REFERENCE VALUE can be substituted for PART AVE to generate graphs indication true bias.
1.00
0.60
Appraiser C Upper Spec
0.40
Lower Spec
0.20
0.00
1 2 3 4 5 6 7 8 9 10
Part Number
Analysis:
1.00
0.80
Appraiser A Appraiser B
0.60
Range
0.20
0.00
1 2 3 4 5 6 7 8 9 10
Part Number
Analysis:
12.00
10.00
8.00
Average
6.00
4.00
2.00
0.00
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Analysis:
12.00
10.00
8.00
Average
6.00
4.00
2.00
0.00
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
Analysis:
Run Chart
1.00
0.90
0.80
0.70
0.60
Value
0.50
0.40
0.30
0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10
Part
Analysis:
Scatter Plot
12.00
10.00
8.00
6.00
4.00
2.00
0.00
Part 1
Part 2
Part 3
Part 4
Part 5
Scatter Plot
12.00
10.00
8.00
6.00
4.00
2.00
0.00
Part 8
Part 6
Part 7
Part 9
Part 10
Analysis:
12.00
10.00
8.00
6.00
4.00
2.00
0.00
1 2 3 4 5 6 7 8 9 10
12.00
10.00
8.00
6.00
4.00
2.00
0.00
1 2 3 4 5 6 7 8 9 10
12.00
10.00
8.00
6.00
4.00
2.00
0.00
1 2 3 4 5 6 7 8 9 10
Analysis:
Error Chart
12
10
8
6
4
2
0
Part 1
Part 2
Part 3
Part 4
Part 5
Error Chart
12
10
8
6
4
2
0
Part 6
Part 7
Part 8
Part 9
Part 10
Analysis:
1
0.8
0.6
Appr A
0.4
0.2
0
0 0 0 0 0 0 0 0 0 0 00 10 20 30 40 50 60 70 80 90 00
.0 .9 .8 .7 .6 .5 .4 .3 .2 .1 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 1.
-1 -0 -0 -0 -0 -0 -0 -0 -0 -0
1
0.8
0.6
Appr B
0.4
0.2
0
0 0 0 0 0 0 0 0 0 0 00 10 20 30 40 50 60 70 80 90 00
.0 .9 .8 .7 .6 .5 .4 .3 .2 .1 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 1.
-1 -0 -0 -0 -0 -0 -0 -0 -0 -0
1
0.8
0.6
Appr C
0.4
0.2
0
0 0 0 0 0 0 0 0 0 0 00 10 20 30 40 50 60 70 80 90 00
.0 .9 .8 .7 .6 .5 .4 .3 .2 .1 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 1.
-1 -0 -0 -0 -0 -0 -0 -0 -0 -0
Analysis:
12.00
10.00
8.00
4.00
2.00
0.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00
Analysis:
Comparison XY Plot
12.00
10.00
8.00
Appr B
6.00
4.00
2.00
0.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00
Appr A
Comparison XY Plot
12.00
10.00
8.00
Appr C
6.00
4.00
2.00
0.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00
Appr A
Comparison XY Plot
12.00
10.00
8.00
Appr C
6.00
4.00
2.00
0.00
0.00 2.00 4.00 6.00 8.00 10.00 12.00
Appr B
Analysis:
X BAR & R
VARIABLES CONTROL CHART
(Format for example only; Supplier created templates may be used)
VARIABLES CONTROL CHART ( x & R ) PART NO. CHART NO.
MEASUREMENT EVALUATION PART NUMBER
PART NAME (Product) OPERATION (Process) SPECIFICATION LIMITS
PART NAME
APPRAISER A APPRAISER B APPRAISER C MACHINE GAGE UNIT OF MEASURE ZERO EQUALS
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
X BAR & R
VARIABLES CONTROL CHART
(Format for example only; Supplier created templates may be used)
VARIABLES CONTROL CHART ( x & R ) PART NO. CHART NO.
MEASUREMENT EVALUATION PART NUMBER
PART NAME (Product) OPERATION (Process) SPECIFICATION LIMITS
PART NAME
APPRAISER A APPRAISER B APPRAISER C MACHINE GAGE UNIT OF MEASURE ZERO EQUALS
PART
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
NUMBER
1
R
E
2
A
D
3
I
N
4
G
S 5
SUM
SUM
x
NUM
HIGH-
R
LOW
X BAR & R
VARIABLES CONTROL CHART
(Format for example only; Supplier created templates may be used)
VARIABLES CONTROL CHART ( x & R ) PART NO. CHART NO.
MEASUREMENT EVALUATION PART NUMBER
PART NAME (Product) OPERATION (Process) SPECIFICATION LIMITS
PART NAME
APPRAISER A APPRAISER B APPRAISER C MACHINE GAGE UNIT OF MEASURE ZERO EQUALS
sm = SQRT ( se + sA )
Thus the number of distinct categories that can be reliably distinguished by these measurements is:
ndc = 1.41 x sp / sm =
This is the number of non-overlapping 97% confidence intervals that will span the range of product variation. (A 97% confidence
interval centered on a single measurement would contain the actual product value that is represented by that measurement 97%
of the time.)
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1 2 3 4 5 6 7 8 9 10
RANGES (R CHART)
r= UCL = LCL =
1.00
0.80
0.60
0.40
0.20
0.00
1 2 3 4 5 6 7 8 9 10
READING 1 2 3 4 5 6 7 8 9 10
VALUE
HIGH-
R n/a 0 0 0 0 0 0 0 0 0
LOW
GAGE R ANALYSIS
Data in control? % Repeatability =
This method CANNOT be used for final gage acceptance without other complete and detailed MSA methods.