PPAP WORKBOOK

Part number: Project name:

Part description: Supplier name:
Revision Level: Supplier Location:
Shown on drawing no: Supplier representative name:
Parent part number (if
applicable): Email: Phone:

Reason for PPAP Tooling Inactive>1 Year PIQ Risk Level High
PPAP Requirements are highlighted Suppliers are not required to use all suggested templates in this workbook.
Submission Level 5

If individual files are used, be sure to include all 18 elements, compress the files in a Zip file to send the electronic information.

PPAP Element PIQ/PPAP 1 2 3 4 5 Date Comments

submitted
1 Design Record R S S * R
2 Authorized Engineering Change Documents R S S * R
3 Customer Engineering Approval (if required) R R S * R
4 Design Failure Mode and Effects Analysis (DFMEA) R R S * R
5 Process Flow Diagram(s) R R S * R
6 Process Failure Mode and Effects Analysis (PFMEA) R R S * R
7 Control Plan R R S * R
8 Measurement System Analysis Studies R R S * R
9 Dimensional Results R S S * R
10 Records of Material / Performance Test Results R S S * R
11 Initial Process Studies R R S * R
12 Qualified Laboratory Documentation R S S * R
13 Appearance Approval Report (AAR) S S S * R
14 Sample Production Parts R S S * R
15 Master Sample R R R * R
16 Checking Aids R R R * R
17 Record of Compliance with Customer-Specific Requirements R R S * R
18 Part Submission Warrant (PSW) (See Appendix B) S S S S R
Appendix
A Retention Requirements Table
B Part Submission Warrant (PSW) Form
C Product Process Change Notification (PPCN) Form
D Restricted Materials

Additional Comments:

Rev 4.0
 SHEET No ISSUE LEVEL ISSUE DATE
PROCESS FLOW CHART 1 of 1

DESCRIPTION CELL / LINE MODIFICATIONS PART No / CUSTOMER

FLOW CHART SYMBOLS

Receipt Critical Process Storage Ship Process Flow

Process Control
Direction
Point

Receive Receive
Part Piston Assembly

Install Retaining Place Piston Swage Piston Centerless Superfinishing Wash & Oil Ship to
Ring Assembly On On Part of Stem Journal to Prevent Rust Assembly
Part

C2C, PPAP Workbook, 5 Process Flow Diagram, Revision A, Released 2014-12-01

 For Make parts, the manufacturing form should be used (or software system, if applicable).
Refer to the AIAG Potential Failure Mode and Effects Analysys reference manual. PFMEA form

Process : Date: Revision:

N° FMEA : Prepared by: Criticity threshold:

R
Existing at this date Corrective Actions Expected results
é
s
Process root Customer Detection Recommended actions / Actions
Process step Process failure mode S O D RPN Responsible Date S O D RPN u
cause effect Prevention to be done
l
What is the process step What do you see in the What are the What is the What are the existing controls What are the actions for reducing

How Severe is the

effect to the
cusotmer?

How often does

How well can you

cause or FM occur?

detect cause or FM?

t
under investigation? factory that tells you the potential ways impact on the and procedures (inspection and the occurrance of the Cause, or a
cause has occurred? the Key Inputs Key Output test) that prevent eith the cause improving detection?
can vary from Variables? or the Failure Mode?
t
desired (Out-of- (Customer s
spec)? Requirements)

0 0

0 0

0 0
0 0

0 0

0 0
0 0
0 0
0 0
0 0

C2C, PPAP Workbook, 6 PFMEA, Revision A, Released 2014-12-01

 0 0

0 0
0 0
0 0
0 0
0 0
0 0

0 0

C2C, PPAP Workbook, 6 PFMEA, Revision A, Released 2014-12-01

R
é
s
u
l
t
a
t
s

C2C, PPAP Workbook, 6 PFMEA, Revision A, Released 2014-12-01

 Severity Evaluation Criteria
Rank Severity Description General Comments
1 None Has no effect on the customer Has no effect. Will not be noticed

2 Very Slight Customer may see but is not annoyed. Defects noticed by the Will not tell friends. Defects can be reworked on line. Fit & finish/squeak &
discriminating customer. rattle item does not conform

3 Minimal Customer will see and may be slightly annoyed. Defects noticed by the Probably will not tell friends. Rework on line but out of station. Fit &
average customer finish/squeak & rattle item does not conform

4 Minor Customer will be slightly annoyed. Defects noticed by the most customer. May tell friends. Might suggest a change to the product. Fit &
The product may have to be sorted and a portion reworked. finish/squeak & rattle item does not conform

5 Moderate Customer will be slightly dissatisfied. 100% of product will be reworked. Will tell friends, would like a change to the product. Less than 15% loss of
May result in scrap further down the line. production

6 Significant Customer will be dissatisfied. Minor disruption in production line. A portion May be a service call. Will result in scrap. Less than 40% loss of
of the product may have to be scrapped. Product has minor damage. production. Will tell friends, may not buy another product, would like a
change to the product.

7 Serious Customer will be very dissatisfied. Production may need to be sorted and Minor SIR machine repair (<20 minutes), will result in additional
scrapped. Production had major damage maintenance time or unplanned downtime less than 1 hour. Will result in
loss of production, over 40%. Customer will not buy another product, may
not buy a product based on floor demonstration models

8 Very Serious Customer will be extremely dissatisfied. Will result in failure without Major SIR or machine repair (>20 minutes), will result in unplanned
warning. 100% of production will be scrapped. machine/line downtime (greater than 1 hour). Will not buy a product based
on floor demonstration models

9 Extremely Serious Safety of consumer at risk or results in minor injury. Is in non-compliance Could result in liability lawsuit, does not meet internal requirements
with voluntary regulatory requirements

10 Hazardous Is life threatening or results in permanent injury. Is non-compliance with Operator will be permanently injuried. Will not be able to sell the product
mandatory government regulatory requirements with government certification. Does meet government requirements
 Occurrence Evaluation Criteria
Ranking Occurrence
1 Extremely Unlikely
2 Unlikely
3 Minimal
4 Very Slight Probability
5 Slight Probability
6 Low Probability
7 Medium Probability
8 Moderately High Probability
9 High Probability
10 Extremely High Probability
Detection Evaluation Criteria
Ranking Ability to Detect
1 Certain
2 Almost Certain
3 High Probability
4 Very likely
5 Likely
6 Moderately Likely
7 May Not
8 Probably Will Not
9 Almost No Porbability
10 No Proability
Description
<0.00005% chance of occurrence (<.5 ppm)
>0.00005% <0.0005% chance of occurrence (.5 - 5 ppm)
>0.0005% <0.005% chance of occurrence (5-50 ppm)
>0.005% <0.05% chance of occurrence (50-500ppm)
>0.05% <0.5% chance of occurrence (500-5000 ppm)
>0.5% < 1% chance of occurrence (5000-10,000 ppm)
> 1% < 2% chance of occurrence(10,000-20,000)
> 2% < 3% chance of occurrence (20,000-30,000 ppm)
> 3% < 4% chance of occurrence (30,000-40,000 ppm)
> 4% chance of occurrence (> 40,000 ppm)
Description
The defect will be caught prior to relesing the design for manufacturing
The defect will not be caught prior to relesing the design for manufacturing
C2C, PPAP Workbook, 6a PFMEA Rankings, Revision A, Released 2014-12-01
Comments
Severity level 10 MUST fall into this area, depending on the compay
policy, a fault tree analysis may be required to prove the chance of failure
is sufficiently low to meet requirements - this requirement should be listed
in the 'recommended action', and results listed in the 'action taken'
Severity level 9 MUST at least fall into this area, depending on the
compay policy, a fault tree analysis may be required to prove the chance
of failure is sufficiently low to meet requirements - this requirement should
be listed in the 'recommended action', and the results listed in the 'action
taken'
Comments
Severity level 10 MUST fall into this area, depending on the compay
policy, a fault tree analysis may be required to prove the chance of failure
is sufficiently low to meet requirements - this requirement should be listed
in the 'recommended action', and the results listed in the 'action taken'
Severity level 9 MUST fall into this area, depending on the compay policy,
a fault tree analysis may be required to prove the chance of failure is
sufficiently low to meet requirements - this requirement should be listed in
the 'recommended action', and the results listed in the 'action taken'
 Document Number: xxxx
Document Name: Revision No. xx
Date Revised: dd mmm yyyy
← Back to Front Page WHIRLPOOL CONTROL PLAN
Supplier is required to employ the below document format for this deliverable, or similar format that provides the same content.
Prototype Pre-launch Production Key Contact / Phone Date (orig.) Date (rev.)
Control Plan Number
Part Number & Latest Change Level Core Team Engineering Approval/Date (if req’d)

Part Name / Description Facility / Process / Supplier Approval & Date Quality Approval / Date

Location / Supplier Location / Supplier Type of Control Plan Other Approval / Date (if req’d)
Code

Characteristics Methods
Special
Part / Process Process Name / Machine, Device, Char. Product/Process Evaluation Sample Reaction
Number Operation Description Tools, Equip. No. Product Process Class Specification/ Measurement Control Method Plan
Tolerance Technique Size Freq.

C2C, PPAP Workbook, 7 Control Plan, Revision A, Released 2014-12-01 Page 8 of 48

 MEASUREMENT SYSTEMS ANALYSIS

REPEATABILITY & REPRODUCIBILITY DATE

GAGE NAME CHARACTERISTIC

GAGE TYPE SPECIFICATION

GAGE NUMBER TEST NUMBER

APPRAISER A NAME APPRAISER B NAME

SAMPLE SIZE 10 APPRAISERS 3 APPRAISER C NAME

TRIALS 3

Gage Repeatability and Reproducibility Data Collection

PART
Appraiser/
Trial # 1 2 3 4 5 6 7 8 9 10 AVG
A
1 0.29 -0.56 1.34 0.47 -0.8 0.02 0.59 -0.31 2.26 -1.36 0.1940
2 0.41 -0.68 1.17 0.5 -0.92 -0.11 0.75 -0.2 1.99 -1.25 0.1660
3 0.64 -0.58 1.27 0.64 -0.84 -0.21 0.66 -0.17 2.01 -1.31 0.2110
AVG'S 0.447 -0.607 1.260 0.537 -0.853 -0.100 0.667 -0.227 2.087 -1.307 X̅a 0.1903
Range 0.350 0.120 0.170 0.170 0.120 0.230 0.160 0.140 0.270 0.110 R̅a 0.1840
B
1 0.08 -0.47 1.19 0.01 -0.56 -0.2 0.47 -0.63 1.8 -1.68 0.0010
2 0.25 -1.22 0.94 1.03 -1.2 0.22 0.55 0.08 2.12 -1.62 0.1150
3 0.07 -0.68 1.34 0.2 -1.28 0.06 0.83 -0.34 2.19 -1.5 0.0890

AVG'S 0.133 -0.790 1.157 0.413 -1.013 0.027 0.617 -0.297 2.037 -1.600 X̅b 0.0683

Range 0.180 0.750 0.400 1.020 0.720 0.420 0.360 0.710 0.390 0.180 R̅b 0.5130
C
1 0.04 -1.38 0.88 0.14 -1.46 -0.29 0.02 -0.46 1.77 -1.49 -0.2230
2 -0.11 -1.13 1.09 0.2 -1.07 -0.67 0.01 -0.56 1.45 -1.77 -0.2560
3 -0.15 -0.96 0.67 0.11 -1.45 -0.49 0.21 -0.49 1.87 -2.16 -0.2840

AVG'S -0.073 -1.157 0.880 0.150 -1.327 -0.483 0.080 -0.503 1.697 -1.807 X̅c -0.2543

Range 0.190 0.420 0.420 0.090 0.390 0.380 0.200 0.100 0.420 0.670 R̅c 0.3280
Part X̿ 0.0014
Average 0.1689 -0.8511 1.0989 0.3667 -1.0644 -0.1856 0.4544 -0.3422 1.9400 -1.5711 Rp 3.5111

([ R̅a = 0.184 ] + [ R̅b = 0.513 ] + [ R̅c = 0.328 ]) / [ # OF APPRAISERS = 3 ] =0.3417 R̿ 0.3417

X̅DIFF = [ Max X̅ = 0.1903 ] - [Min X̅ = -0.2543 ] = 0.4446 X̅DIFF 0.4446

* UCLR = [ R̿ = 0.3417 ] x [D4 = 2.58 ] = 0.8816 UCLR 0.8816

* 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 apprasier and unit as originally used
or
discard values and re-average and recompute R̿ and the limiting value from the remaining observations.

Notes：
 Gage Repeatability and Reproducibility Report

Part # / Name: Gage Name: Date:

Characteristics: Gage No:

Performed by:
Specifications: Gage Type:

From data sheet: R̿ = 0.3417 X̅DIFF = 0.4446 RP = 3.5111

MEASUREMENT UNIT ANALYSIS % TOTAL VARIATION (TV)

REPEATABILITY - EQUIPMENT VARIATION (EV) %EV = 100 [ EV / TV ]

EV = R̿ x K1 Trials K1 = 100 0.2019 / 1.1461

EV = 0.3417 X 0.5908 2 0.8862
EV = 0.2019 3 0.5908 = 17.61 %

REPRODUCIBILITY - APPRAISER VARIATION (AV) X̅DIFF 0.4446

K2 0.5231 %AV = 100 [ AV / TV ]
2 2
AV = ( X DIFF  K 2 )  ( EV /( nr )) EV 0.2019
n 10 = 100 0.2296 / 1.1461
r 3
AV = 0.2296 = 20.04 %
Appraisers 2 3
K2 0.7071 0.5231

REPEATABILITY & REPRODUCIBILITY (GRR) %GRR = 100 [ GRR / TV ]

Part K3

GRR = EV 2  AV 2 = 100 0.3058 / 1.1461

2 0.7071

= 0.3058 = 26.68 %
3 0.5231

4 0.4467
PART VARIATION (PV) %PV = 100 [ PV / TV ]

5 0.4030
PV = R P x K3 = 100 1.1046 / 1.1461
= 3.511 X 0.3146
6 0.3742
= 1.1046 = 96.38 %

7 0.3534

TOTAL VARIATION (TV) ndc = 1.41 [ PV / GRR ]

8 0.3375

TV = GRR 2  PV 2 = 1.41 1.1046 / 0.3058

9 0.3249

= 1.1461 = 5.0939
10 0.3146
 BIAS STUDY

Instructions:
Standard Standard
1) Input the reference value n Average
Deviation σr Deviation σb
2) Measure the piece several times
3) Check for unacceptable bias Value 15 6.0667 0.3132 0.0809

Reference Value = 6.00, a = .05

Significant t 95% Confidence Interval of

t df value (2- Average Bias the Bias
Statistic
tailed) Lower Upper
Value 0.8244 14 2.1448 0.0667 -0.1068 0.2401

Reference Value 6.00

Measured BIAS OK
Trial#
Value
Bias
1 5.8 -0.2
2 5.7 -0.3
3.5
3 5.9 -0.1
4 5.9 -0.1 F 3
r
5 6.9 0.9 e
q 2.5
6 6.1 0.1 u
e 2
7 6.0 0.0 n
c
8 6.1 0.1 y 1.5
9 6.4 0.4
10 6.3 0.3 1
11 6.0 0.0
0.5
12 6.1 0.1
13 6.2 0.2 0
14 5.6 -0.4 5.6 5.7 5.8 5.9 6 6.1 6.2 6.3 6.4 6.9
15 6.0 0.0 Measured Values
 LINEARITY STUDY

1 2 3 4 5

Part Reference Value 2.00 4.00 6.00 8.00 10.00

1 2.70 5.10 5.80 7.60 9.10

2 2.50 3.90 5.70 7.70 9.30

3 2.40 4.20 5.90 7.80 9.50

4 2.50 5.00 5.90 7.70 9.30

T
5 2.70 3.80 6.00 7.80 9.40
R
I 6 2.30 3.90 6.10 7.80 9.50
A 7 2.50 3.90 6.00 7.80 9.50
L 8 2.50 3.90 6.10 7.70 9.50
S
9 2.40 3.90 6.40 7.80 9.60

10 2.40 4.00 6.30 7.50 9.20

11 2.60 4.10 6.00 7.60 9.30

12 2.40 3.80 6.10 7.70 9.40

1 2 3 4 5

Part Reference Value 2.00 4.00 6.00 8.00 10.00

1 0.70 1.10 -0.20 -0.40 -0.90
2 0.50 -0.10 -0.30 -0.30 -0.70
3 0.40 0.20 -0.10 -0.20 -0.50
4 0.50 1.00 -0.10 -0.30 -0.70
5 0.70 -0.20 0.00 -0.20 -0.60
B 6 0.30 -0.10 0.10 -0.20 -0.50
I
7 0.50 -0.10 0.00 -0.20 -0.50
A
S 8 0.50 -0.10 0.10 -0.30 -0.50
9 0.40 -0.10 0.40 -0.20 -0.40
10 0.40 0.00 0.30 -0.50 -0.80
11 0.60 0.10 0.00 -0.40 -0.70
12 0.40 -0.20 0.10 -0.30 -0.60
Average 0.4917 0.1250 0.0250 -0.2917 -0.6167

1.50
LINEARITY NOT OK

1.00

0.50

0.00
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00

-0.50

-1.00

-1.50
Value Frequency
5.6 1
5.7 1
5.8 1
5.9 2
6 3
6.1 3
6.2 1
6.3 1
6.4 1
6.9 1
 a= -0.13167 0.73667 =b
slope SE 0.01093 0.07252 Int SE
R-Square= 0.71432 0.23954 y SE
F= 145.02324 58 =df
SSReg= 8.32133 3.32800 =SSResid

T inv 2.0017175
Delta y 0.061902

p-Value 2.038E-17 1.734E-14

Sxx 480

Master Y Measure Avg Bias Y Pred Ci Calculator 95% Lower 95% Higher
2.00 0.70 0.4917 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.50 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.40 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.50 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.70 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.30 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.50 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.50 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.40 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.40 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.60 0.473333333 0.107217443 0.36611589 0.580550777
2.00 0.40 0.473333333 0.107217443 0.36611589 0.580550777
4.00 1.10 0.1250 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 0.20 0.21 0.075814181 0.134185819 0.285814181
4.00 1.00 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.20 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 0.00 0.21 0.075814181 0.134185819 0.285814181
4.00 0.10 0.21 0.075814181 0.134185819 0.285814181
4.00 -0.20 0.21 0.075814181 0.134185819 0.285814181
6.00 -0.20 0.0250 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 -0.30 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 -0.10 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 -0.10 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.00 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.10 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.00 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.10 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.40 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.30 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.00 -0.05333333 0.06190202 -0.11523535 0.008568686
6.00 0.10 -0.05333333 0.06190202 -0.11523535 0.008568686
8.00 -0.40 -0.2917 -0.31666667 0.075814181 -0.39248085 -0.24085249
8.00 -0.30 -0.31666667 0.075814181 -0.39248085 -0.24085249
8.00 -0.20 -0.31666667 0.075814181 -0.39248085 -0.24085249
8.00 -0.30 -0.31666667 0.075814181 -0.39248085 -0.24085249
8.00 -0.20 -0.31666667 0.075814181 -0.39248085 -0.24085249
8.00 -0.20 -0.31666667 0.075814181 -0.39248085 -0.24085249
 ← Back to Front Page

Supplier may employ the below document format in addition to the required MSA
Instructions:
1) Add reference information to cells highlighted in light yellow:

2) Add required information to all cells highlighted in gold:

Note: Sample data is only required for the number of samples and trials actually run - you may leave some gold boxes empty.

3) Results are shown in cells highlighted in light blue:

4) Manually adjust the scale on the Averages Chart so the control limits are wide enough to see the variation.

Note:You may unprotect this worksheet should you wish to modify it: select Tools, then Protection, then Unprotect Sheet

MEASUREMENT SYSTEMS ANALYSIS

REPEATABILITY & REPRODUCIBILITY DATE

GAGE NAME CHARACTERISTIC

GAGE TYPE SPECIFICATION

GAGE NUMBER TEST NUMBER

APPRAISER A NAME APPRAISER B NAME

SAMPLE SIZE 10 APPRAISERS 3 APPRAISER C NAME

TRIALS 3

Appraiser/
Trial # 1 2 3 4 5 6 7 8 9 10 AVG
A
1 0.29 -0.56 1.34 0.47 -0.8 0.02 0.59 -0.31 2.26 -1.36 0.194
2 0.41 -0.68 1.17 0.5 -0.92 -0.11 0.75 -0.2 1.99 -1.25 0.166
3 0.64 -0.58 1.27 0.64 -0.84 -0.21 0.66 -0.17 2.01 -1.31 0.211
AVG'S 0.447 -0.607 1.260 0.537 -0.853 -0.100 0.667 -0.227 2.087 -1.307 Xa 0.190

Range 0.350 0.120 0.170 0.170 0.120 0.230 0.160 0.140 0.270 0.110 Ra 0.184
B
1 0.08 -0.47 1.19 0.01 -0.56 -0.2 0.47 -0.63 1.8 -1.68 0.001
2 0.25 -1.22 0.94 1.03 -1.2 0.22 0.55 0.08 2.12 -1.62 0.115
3 0.07 -0.68 1.34 0.2 -1.28 0.06 0.83 -0.34 2.19 -1.5 0.089
AVG'S 0.133 -0.790 1.157 0.413 -1.013 0.027 0.617 -0.297 2.037 -1.600 Xb 0.068
Range 0.180 0.750 0.400 1.020 0.720 0.420 0.360 0.710 0.390 0.180 Rb 0.513
C
1 0.04 -1.38 0.88 0.14 -1.46 -0.29 0.02 -0.46 1.77 -1.49 -0.223
2 -0.11 -1.13 1.09 0.2 -1.07 -0.67 0.01 -0.56 1.45 -1.77 -0.256
3 -0.15 -0.96 0.67 0.11 -1.45 -0.49 0.21 -0.49 1.87 -2.16 -0.284
AVG'S -0.073 -1.157 0.880 0.150 -1.327 -0.483 0.080 -0.503 1.697 -1.807 Xc -0.254
Range 0.190 0.420 0.420 0.090 0.390 0.380 0.200 0.100 0.420 0.670 Rc 0.328
Part X 0.001
Average 0.1689 -0.8511 1.0989 0.3667 -1.0644 -0.1856 0.4544 -0.3422 1.9400 -1.5711 Rp 3.511
RANGE VARIATION
Ra 0.184 # Trials D4 Rdoublebar x (D4) = UCLR
Rb 0.513 2 3.267 0.3417 2.575 = 0.880
Rc 0.328 3 2.575 Note: LCL is zero with < 8 trials
SUM 1.025
Rdoublebar 0.3417 # Trials A2 Xbar + ( Rbar x A2) = UCLX
2 1.880 0.0014 0.3417 1.023 = 0.351
3 1.023 Xbar - ( Rbar x A2) = LCLX
0.0014 0.3417 1.023 = -0.348

Max. X 0.190 Tolerence = 15 # Trials - n = 10

Min. X -0.254
X Diff 0.445 # Appr. - r = 3

GAGE TYPE DATE

TEST NUMBER APPRAISER A NAME

APPRAISER B NAME

APPRAISER C NAME

MEASUREMENT UNIT ANALYSIS % TOTAL VARIATION (TV)

REPEATABILITY - EQUIPMENT VARIATION (EV) % EV = 100 (EV/TV)

% EV = 17.65%
EV = R1 X K1 K1 (3 trials)= 3.05
EV = 1.0420833 Percent of Tolerance: 100(EV/Tol) = 6.9%

REPRODUCIBILITY - APPRAISER VARIATION (AV)

% AV = 100(AV/TV)
AV = SQ. ROOT ((X DIFF X K2)SQUARED - (EV SQUARED/NR)) % AV = 20.08%
AV = 1.1854292 K2 (3 appraisers)= 2.70
Percent of Tolerance: 100(AV/Tol) = 7.9%

REPEATABILITY & REPRODUCIBILITY (R&R) % R&R = 100(R&R/TV)

% R&R = 26.74%
R&R = SQ. ROOT (EV SQUARED + AV SQUARED)
R&R = 1.5783473 Percent of Tolerance: 100(R&R/Tol) = 10.5%

PART VARIATION (PV) % PV = 100(PV/TV)

% PV = 96.36%
PV = Rp x K3 PARTS K3
PV = 5.688 10 1.62 Percent of Tolerance: 100(PV/Tol) = 37.9%

TOTAL VARIATION (TV)

TV = SQ. ROOT(R&R SQUARED + PV SQUARED)

TV = 5.902925
 MEASUREMENT SYSTEMS EVALUATION

Discrimination OK
UCLR 0.880
Ranges Chart 0 MSA with appraiser A is SPC
Min D 0.09 1 MSA with appraiser B is not SPC
Min D Accepted 5 0 MSA with appraiser C is SPC
D 9.775463

1.200

1.000
Range

0.800

0.600

0.400

0.200

0.000
1 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 7 8 9 1
0 0 0
Trial Number
A B C UCL Mean

Averages Chart
Appraiser A: 8 points out of UCL/LCL - Measurement System is able to distinguish variation among the samples. MSA OK
Appraiser B: 7 points out of UCL/LCL - Measurement System is able to distinguish variation among the samples. MSA OK
Appraiser C: 7 points out of UCL/LCL - Measurement System is able to distinguish variation among the samples. MSA OK

2.500
2.000
1.500
1.000
Average

0.500
0.000
-0.500 1 2 3 4 5 6 7 8 9 1
-1.000 0
-1.500
-2.000
-2.500

Trial Number
A B C UCL Mean
REPEATABILITY - EQUIPMENT VARIATION (EV)

REPRODUCIBILITY - APPRAISER VARIATION (AV)

REPEATABILITY & REPRODUCIBILITY (R&R)
PART VARIATION (PV)
TOTAL VARIATION (TV)

n / TV n / Tol
EV 17.65% 7%
AV 20.08% 8%
R&R 26.74% 11%
PV 96.36% 38%

TV 5.902925047

Appraiser 1 0 3 4 5 6 7 8 9 10 Min Value

A 0.350 0.000 0.170 0.170 0.120 0.230 0.160 0.140 0.270 0.110 0
B 0.180 0.000 0.400 1.020 0.720 0.420 0.360 0.710 0.390 0.180 0
C 0.190 0.000 0.420 0.090 0.390 0.380 0.200 0.100 0.420 0.670 0
0
Subgroup
Minimal
Size (n)
D value Accepted
2 4
3 5
4 5
5 5
6 6
7 6
8 6
9 6
10 6
 Trials K1
2 4.56
3 3.05

Appraisers K2
2 3.65
3 2.70

Parts K3
2 3.65
3 2.70
4 2.30
5 2.08
6 1.93
7 1.82
8 1.74
9 1.67
10 1.62
 Rbar UCL Xbar
1 0.350 0.3417 0.879791667 0.447 0.001
2 0.120 0.3417 0.879791667 -0.607 0.001
3 0.170 0.3417 0.879791667 1.260 0.001
4 0.170 0.3417 0.879791667 0.537 0.001
5 0.120 0.3417 0.879791667 -0.853 0.001
6 0.230 0.3417 0.879791667 -0.100 0.001
7 0.160 0.3417 0.879791667 0.667 0.001
8 0.140 0.3417 0.879791667 -0.227 0.001
9 0.270 0.3417 0.879791667 2.087 0.001
10 0.110 0.3417 0.879791667 -1.307 0.001
0.3417 0.879791667 0.001
1 0.180 0.3417 0.879791667 0.133 0.001
2 0.750 0.3417 0.879791667 -0.790 0.001
3 0.400 0.3417 0.879791667 1.157 0.001
4 1.020 0.3417 0.879791667 0.413 0.001
5 0.720 0.3417 0.879791667 -1.013 0.001
6 0.420 0.3417 0.879791667 0.027 0.001
7 0.360 0.3417 0.879791667 0.617 0.001
8 0.710 0.3417 0.879791667 -0.297 0.001
9 0.390 0.3417 0.879791667 2.037 0.001
10 0.180 0.3417 0.879791667 -1.600 0.001
0.3417 0.879791667 0.001
1 0.190 0.3417 0.879791667 -0.073 0.001
2 0.420 0.3417 0.879791667 -1.157 0.001
3 0.420 0.3417 0.879791667 0.880 0.001
4 0.090 0.3417 0.879791667 0.150 0.001
5 0.390 0.3417 0.879791667 -1.327 0.001
6 0.380 0.3417 0.879791667 -0.483 0.001
7 0.200 0.3417 0.879791667 0.080 0.001
8 0.100 0.3417 0.879791667 -0.503 0.001
9 0.420 0.3417 0.879791667 1.697 0.001
10 0.670 0.3417 0.879791667 -1.807 0.001
Min D Second Min 1 0 3 4 5 6 7 8 9 10
0.11 0.11 0.35 0.17 0.17 0.12 0.23 0.16 0.14 0.27 0.11
0.18 0.18 0.18 0.4 1.02 0.72 0.42 0.36 0.71 0.39 0.18
0.09 0.09 0.19 0.42 0.09 0.39 0.38 0.2 0.1 0.42 0.67
0.09 0.09
UCL LCL
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
0.351 -0.348
 Whirlpool Part Number: Production Part Approval, Dimension Results
Part Name:
Whirlpool Drawing Number:
Whirlpool Engineering Revision Level:
Additional Engineering Changes:
Organization Name: Submitter Name (Print):
Supplier Code: Supplier Signature:
Supplier Location: Title:
Inspection Facility: Date:

Supplier is required to employ the below document format for this PPAP deliverable, or similar format that Organization Measurement Results (Data)
provides the same content. (Add more sample columns as needed.)
Item Dimension / Specification Specification Limits Test Date Qty Tested Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 Sample 7

C2C, PPAP Workbook, 9 Dimensional Results, Revision A, Released 2014-12-01

OK / Not OK

C2C, PPAP Workbook, 9 Dimensional Results, Revision A, Released 2014-12-01

 Whirlpool Part Number: Pro
Part Name:
Whirlpool Drawing Number:
Whirlpool Engineering Revision Level:
Additional Engineering Changes:
Name of Laboratory:
Organization Name: Subm
Supplier Code: S
Supplier Location:
Material Supplier:

Supplier is required to employ the below document format for this deliverable, or similar format that
provides the same content.
Material or Test Spec. No / Rev / Date Specification Limits Test Date Qty Tested

C2C, PPAP Workbook, 10 Matl Perf Test Results, Revision A, Released 2014-12-01
 Production Part Approval, Dimension Results

Submitter Name (Print):

Supplier Signature:
Title:
Date:

Supplier Test Results (Data) / Test Conditions

(Add more sample columns as needed.)
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6 Sample 7 OK / Not OK

C2C, PPAP Workbook, 10 Matl Perf Test Results, Revision A, Released 2014-12-01
age
Enter Title or Comments Process Capability Study

Supplier Name: Fill out all fields in Yellow

Part Number: Print Revision: Characteristic:

test
Part Description: Measurement Device:

Supplier is required to employ the below document format for this deliverable, or similar format that provides the same content.

140
X-Bar Chart Histogram
120
6.00 0.25

100
5.00
0.2
80
4.00
Within 0.15
60 Overall
3.00

40 0.1
2.00

20 0.05
1.00

0
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 0.00 0

Range Chart Probability of Normality = 0.002

9 4
8 3
7 2
6
1
5
0
4
-1
3
2 -2

1 -3

0 -4
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 -100 -50 0 50 100 150 200

Specify Special Characteristic Level for Boated dimensions

Process Data Capability / Performance

Impact
USL 23.5 Max Value 126 St Dev (R̅/d2) 1.7196905 Capability Performance
LSL 23.5 Min Value 2 St Dev (Indiv.) 36.228442 Cp 0.19 Pp 0.01 Critical
# of Samples 125 Range 124 UCL X 66.308 CpU -7.85 PpU -0.37
# of Sub Groups 0 X̿ 64.000 LCL X 61.692 CpL 8.24 PpL 0.39 CC
Sub Group Size (n) 5 R̅ 4.00 UCL R 8.456 Cpk -7.85 Ppk -0.37
 ← Back to Front Page

Supplier is required to employ the below document format for this PPAP deliverable. Save a copy to the Zip folder w
Report"

APPEARANCE APPROVAL REPORT

END ITEM E/C SUPPLIER MANUFACTURING
NUMBER LEVEL NAME LOCATION
COMPONENT E/C SUPPLIER SUPPLIER
PART NUMBER LEVEL CONTACT PHONE
COMPONENT SUPPLIER BUYER
NAME CODE CODE
SURFACE AND TEXTURE EVALUATION
TEXTURE TEXTURE TEXTURE LOCATION
APPROVALS
ID SOURCE ON PART
DESIGN STUDIO
PRE-TEXTURE
SURFACE
ENGINEERING PRE-
TEXTURE
CONCURRENCE
MASTERING STUDIO
TEXTURE
ORIENTATION
MASTERING STUDIO
POST TEXTURE
ORNAMENTATION AND
GRAPHICS
BASE OR RAW MATERIAL SPEC. # AND SUPPLIER / SUPPLIER # / LOT #
MATERIAL, COLOR AND GLOSS EVALUATION
PAINT OR COLORANT VISTEON SPEC. # AND SUPPLIER / SUPPLIER # / LOT #

MASTER REF. MASTER CUSTOMER COM

TRISTIMULUS & GLOSS PART DATA

# COLOR TYPE DATE DL* Da* Db* De* CMC GLS

SUPPLIER APPROVAL PHONE

SIGNATURE
ORNAMENTATION, GRAPHICS AND SURFACE TACTILITY
TYPE OF ORNAMENTATION CUSTOMER APPROVAL
AND GRAPHICS REQUIRED SIGNATURE

COMMENTS:
CUSTOMER INTERIM APP
SIGNATURE:

CUSTOMER FINAL APPRO

BOLD BOXED AREAS FOR CUSTOMER USE ONLY
SIGNATURE
e. Save a copy to the Zip folder with the filename "Appearance Approval

VAL REPORT
MANUFACTURING
DATE
LOCATION
SUPPLIER APPLICATION
PHONE (VEHICLE)
BUYER CUSTOMER
CODE ENGINEER
E EVALUATION
N CUSTOMER REPRESENTATIVE SIGNATURE AND
APPROVALS
DATE
DESIGN STUDIO
PRE-TEXTURE
SURFACE
ENGINEERING PRE-
TEXTURE
CONCURRENCE
MASTERING STUDIO
TEXTURE
ORIENTATION
MASTERING STUDIO
POST TEXTURE
ORNAMENTATION AND
NOT REQ’D  REQ’D 
GRAPHICS

OSS EVALUATION

APPROVAL CUSTOMER
CUSTOMER COMMENTS
RT DATA STATUS INITIALS/DATE
MC GLS A R

PHONE DATE

D SURFACE TACTILITY
CUSTOMER APPROVAL DATE
SIGNATURE

CUSTOMER INTERIM APPROVAL DATE

SIGNATURE:

CUSTOMER FINAL APPROVAL DATE

SIGNATURE
 ← Back to Front Page

Requirement** Submission Level Comments - Whirlpool

Level Level Level Level Level
1 2 3 4*** 5

1. Design Record R S S * R
- For proprietary R R S * R
components/details
- For all other R S S * R
components/details
2. Engineering Change R S S * R
Documents, if any
3. Customer Engineering R R S * R
approval, If required
4. Design FMEA R R S * R The product design-responsible
organization shall develop a Design
FMEA;
For NAR, may be retained in WQMS
5. Process Flow Diagrams R R S * R For NAR make parts, may be retained in
WQMS
6. Process FMEA R R S * R For NAR make parts, may be retained in
WQMS
7. Control Plan R R S * R Early Containment Plan, if requested by
Whirlpool, needs to be included with the
Control Plan;
For NAR make parts, may be retained in
WQMS
8. Measurement System R R S * R Measurement System Evaluation (MSE)
Analysis Studies or Repeatability and Reproducibility
(R&R) may be used
9. Dimensional Results R S S * R
10. Material, Performance R S S * R
Test Results
11. Initial Process Studies R R S * R Capability requirements (Cpk) are to be
met for the entire life of the product and
should be demonstrated by supplier at
any time upon Whirlpool request.
12. Qualified Laboratory R S S * R For Whirlpool Engineering Labs,
Documentation documentation may be retained by the
lab.
13. Appearance Approval S S S * R Requires Whirlpool engineering or design
Report (AAR), if applicable approval, if applicable (e.g., Whirlpool
Color Lab Approval)
14. Sample Product R S S * R
15. Master Sample R R R * R
16. Checking Aids R R R * R If requested by Whirlpool
17. Record of Compliance R R S * R GES0084 Whirlpool Specification –
With Customer-Specific Restricted Materials; Regional Materials
Requirements Regulatory Compliance Requirements;
Build by the customer (Whirlpool), if
requested
18. Part Submission Warrant S S S S R
(PSW)
Bulk Material Checklist S S S S R For bulk materials

S = the organization shall submit to the customer and retain a copy of records or documentation items at appropriate
locations.
R = The organization shall retain at appropriate locations and make available to the custom upon request.
* = The organization shall retain at appropriate locations and submit to the customer upon request.
 requested
18. Part Submission Warrant S S S S R
(PSW)
Bulk Material Checklist S S S S R For bulk materials

S = the organization shall submit to the customer and retain a copy of records or documentation items at appropriate
locations.
R = The organization shall retain at appropriate locations and make available to the custom upon request.
* = The organization shall retain at appropriate locations and submit to the customer upon request.
 le
esign

WQMS
etained in

etained in

uested by
ed with the

etained in

tion (MSE)
cibility

are to be
roduct and
upplier at
est.
bs,
ed by the

ng or design
Whirlpool

on –
Materials
rements;
ool), if

propriate
propriate
C:\Users\pereze9\
RESPALDO Xyomar
 Double-Click to edit, save, and print Part Submission Warrant.
← Back to Front Page Required for all PPAP submission. Save a copy to the Zip folder with
the filename "Part Submission Warrant"

Supplier is required to employ the below document format for this deliverable, or similar format that provides the same content.
Part Name Whirlpool Part Number
Whirlpool Drawing Number Purchase Order No. (if applicable)
Whirlpool Eng. Rev. Level Eng. Rev. Date Windchill Package # (if applic.) Weight (kg)
Additional Engineering Changes Engineering Change Dated
Checking Aid No. Checking Aid Engineering Change Level / Date:
ORGANIZATION MANUFACTURING INFORMATION WHIRLPOOL SUBMITTAL INFORMATION

Organization Name & Supplier Code Whirlpool Name / Division

Street Address Whirlpool Buyer (not applicable if Whirlpool produced)

City Region Postal Code Country Whirlpool Supplier Development Engineer-SDE (For Med High Risk purchase

Supplier Part Number (if applicable): Whirlpool Division Quality Representative

or
High Risk Medium Risk Low Risk Whirlpool Produced Application
Non-Whirlpool Produced (Purchased)

MATERIALS REPORTING
Does the part meet the latest revision of GES0084 Whirlpool Specification – Restricted Materials? Yes No n/a
Does the part meet the Regional Safety, Materials, other Regulatory Requirements as specified? List below: Yes No n/a

Are polymeric parts identified with appropriate ISO marking codes? Yes No n/a
REASON FOR SUBMISSION (Check at least one)
Initial Submission Change to Optional Construction or Material
Engineering Change(s) Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or Additional Change in Part Processing
Correction or Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Other – please specify:
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 – Warrant with product samples and limited supporting data submitted to customer.
Level 3 – Warrant with product samples and complete supporting data submitted to customer.
Level 4 – Warrant and other requirements as defined by customer.
Level 5 – Warrant with product samples and complete supporting data reviewed at organization’s manufacturing location.
SUBMISSION RESULTS
The results for dimensional requirements material and functional tests appearance criteria statistical process package
These results meet all design record requirements: Yes No (If “No” – Explanation Required)
Mold / Cavity / Production Process
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts which were made by a process that meets all Production Pa
th
Approval Process Manual 4 Edition Requirements. I further affirm that these samples were produced at the production rate of _____ pcs/ ___
hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this
declaration below. EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered? Yes Tool Identification #(s): No
Organization Authorized Signature Date
Print Name Phone No. FAX No.
Title E-mail

FOR WHIRLPOOL USE ONLY

PPAP Warrant Disposition: Approved Rejected Other (Interim)
Review with Manufacturing Supplier Quality Representative for Medium / High Risk Purchased Parts: Yes No n/a
If Yes, name of Manufacturing Supplier Quality Representative
Whirlpool Signature Date
(Supplier Development Engineer - SDE for Med/High Risk purchased parts; Division Quality for Low Risk purchased parts or Whirlpool produced parts)
Print Name
Print Name Phone No. FAX No.
Title E-mail

FOR WHIRLPOOL USE ONLY

PPAP Warrant Disposition: Approved Rejected Other (Interim)
Review with Manufacturing Supplier Quality Representative for Medium / High Risk Purchased Parts: Yes No n/a
If Yes, name of Manufacturing Supplier Quality Representative
Whirlpool Signature Date
(Supplier Development Engineer - SDE for Med/High Risk purchased parts; Division Quality for Low Risk purchased parts or Whirlpool produced parts)
Print Name
 Submission Warrant.
opy to the Zip folder with
n Warrant"

he same content.

Weight (kg)

produced)

DE (For Med High Risk purchased)

es No n/a
es No n/a

es No n/a

or Material
ge

ation

tomer.

g location.

statistical process package

that meets all Production Part

tion rate of _____ pcs/ ____
ny deviations from this

No

No n/a

Date
ol produced parts)
 No n/a

Date
ol produced parts)
 Double-Click to edit and print Product Process Change Notification. Requir
← Back to Front Page for all PPAP submission. Save a copy to the Zip folder with the filename
"Product Process Change Notification"

Supplier is required to employ the below document format for this deliverable, or similar format that provides the same content.
Complete this form and email to your customer organization whenever customer notification is required by the PPAP Manua
in Table 3.1. Your customer will respond back with an acknowledgement and may request additional change clarification or
PPAP submission requirements.

To: Customer: Whirlpool Corporation

Organization Part Number: Engineering Revision Level: Dated:

Whirlpool Part Number: Engineering Revision Level: Dated:
Purchase Order Number: Safety and/or government regulation:

Application:

ORGANIZATION MANUFACTURING INFORMATION

Name: Code:
Street Address:
City, State & Zip: Change Type (check all that apply)
Dimensional
Whirlpool Plants Affected: Materials
Functional
Design Responsibility: Whirlpool Organization Appearance

Organization Change That May Affect End Item:

Product Change Engineering Drawing Change New or Revised Subcomponent

Expected PPAP Completion/Submission Date:

DETAILED DESCRIPTION OF PRODUCT/PROCESS CHANGE:

Planned Date of Implementation:

DECLARATION
I hereby certify that representative samples will be manufactured using the revised product and/or process and verified, where appropriate, for
dimensional change, appearance change, physical property change, functionally for performance and durability. I also certify that documented
evidence of such compliance is on file and available for customer review.

Explanation/Comments:

NAME: TITLE:

BUSINESS PHONE NO: FAX NO:

E-MAIL: DATE:

NOTE: Please submit this notification at least 6 weeks prior to the planned change implementation!

Contact your customer to determine if this form is available in an electronic format or if this form should be faxed.
BUSINESS PHONE NO: FAX NO:

E-MAIL: DATE:

NOTE: Please submit this notification at least 6 weeks prior to the planned change implementation!

Contact your customer to determine if this form is available in an electronic format or if this form should be faxed.
nge Notification. Required
older with the filename
cation"

he same content.
red by the PPAP Manual
l change clarification or

Dated:
Dated:

all that apply)

ubcomponent

fied, where appropriate, for

o certify that documented

ould be faxed.
ould be faxed.
 Double-Click to edit and print Global Restricted Materials document.
← Back to Front Page Required for all PPAP submission.

Supplier is required to employ the below document format for this deliverable, or similar format that provides the same content.
 Materials document.
ion.

he same content.