[xls]process capability analysis - cooper industries · web viewtitle process capability analysis...

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3

Cooper Part Number Part Description Supplier NameRevision Level Cooper Purchasing Rep. Submission Date

Primary Manufacturing Site Purchasing Rep Phone # PPAP Due Date

Leve

l 1Le

vel 2

Leve

l 3

Leve

l 5

Required Documents Assigned to Internal Due Date Comments/Concerns/Questions Incl

uded

1 AR Cooper PSW Required

2 AR

3 AR AR

4

5 AR AR AR

6 Process Flow Diagrams AR Any standard flowchart format.

7 Process FMEA AR

8 Control Plan AR

9 AR AR

10 Dimensional Results AR

11 AR AR

12 AR AR

13 AR

14 AR AR AR AR AR AIAG format AAR

15 Sample Product Parts AR

16 Master Samples Required only for level 5

17 Checking aids AR

18

a Tooling Information Form AR

b Packaging Form AR

c IA IA IA IA Specific ASC Format e

d IA IA IA IA

e Supplier PPAP Checklist AR

Required for PPAP submission Not required Documents on a case by case basis are marked AR for "As Requested" IF Applicable

PPAP Production Part Approval

Process

Submission RequirementsSupplier Checklist

Submission Level(Please Type 1-5)

Elem

ent

Ord

er

PPAP RequirementsAIAG PPAP Fourth Edition

Important: Submit your documents in this order.

Leve

l 4

Part Submission Warrant (PSW)

Design Records & Bubbled part print(s).

TWO Cooper Divisional Parts Prints

Approved Engineering Change Documentation

Various engineering documentation

Customer Engineering Approvals

Not Required for Cooper Submissions

Design FMEA, Can be Cooper FMEA Format or an AIAG compliant DFMEA.

Can be Cooper PFMEA Format or an AIAH compliant PFMEA.

Can be Cooper supplied format or AIAG compliant format.

Measurement System Analysis Studies

Cooper GRR format or any statistical package format for gage R&R.

Must be on Cooper Dimensional report format

Material, Performance Test Results

Industry Standard reports or test result formats designated by Cooper Industries.

Initial Process Study (Cpk)Capability Studies

Process Capability Study using any statistical package or Cooper Capability Data Forms.

Qualified Laboratory Documentation

Lab Scope and outside lab proof of accreditation.

Appearance Approval Report

Parts tagged in accordance with Cooper PPAP reference manual

Checking aid design prints and GRR for checking fixtures.

Customer Specific Requirements

Documents as specified by Cooper Industries

Specific document required by Cooper Industries.


Inspection Plan(ASC Suppliers only)

Specification Deviation Form



YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

AR IA

YES

Part Submission WarrantPart Name Cooper Part Number

Engineering Drawing Revision Level Dated

Additional Engineering Changes Dated

Shown on Drawing Number Purchase Order No. Weight (kg)

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Supplier Company Name Supplier Vendor Number Customer Name:

Additional Manufacturing Sites Cooper Manufacturing Locations using the part (list all)

Street Address Purchasing Representative Purchasing Office

City State Zip PPAP Due Date: SOP Date

Does this part utilize Cooper owned tooling? Is it properly identified?

Does this part contain any restricted substances or require IMDS submission? Substance(s)?

IMDS NumberAre plastic or polymeric parts identified with appropriate ISO marking codes?

REASON FOR SUBMISSIONInitial submission (New Parts and Part Number Changes) New Supplier, New material or new source for existing materialEngineering Change: New/Revised drawing or other specification Change of supplier, material or non-equivalent materials/services

New process or a change in production process or method Correction of Non-conformance or discrepancy Change of manufacturing location, sub-supplier or additional location

Change to optional construction, material or component Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

DEFAULT COOPER SUBMISSION LEVEL

SUBMISSION RESULTSThe results for dimensional measurements material and functional tests appearance criteria statistical process package

These results meet all drawing and specification requirements: (If "NO" - Explanation Required in Explanation/comments section below )

Is this a multicavity tool? How many Cavities/Spindle (for molds or dies) ? Number of parts submitted by cavity/spindle

DECLARATIONI affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 4th Edition

requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regular production

process. The data and samples were produced at the production rate of in on Any deviations to this warrant submission

are noted below in the explanation/comments section. #parts # hours date

EXPLANATION/COMMENTS:

Print Name: Job Title Phone No. Fax No.

Supplier Authorized Signature Date Email

FOR COOPER INDUSTRIES USE ONLY

Quality/Supplier Quality Date

Initial Part Warrant Disposition:Quality/Supplier Quality Management Date

Expires:

Final Part Warrant Disposition:Quality or Supplier Quality Date

Print Approver Name: Cooper PPAP Tracking Number:

Safety and/or Government Regulation

If yes, P.O. #

Tooling: transfer, replacement (new), refurbishment, modified or additional

Level 1 - Warrant only submitted to the customer (Applied to non-critical parts and raw bulk material)Level 2 - Warrant with product samples amd limiting supporting data. (Applied to critical bulk product and simple changes)

Level 3 - Warrant with product samples and complete supporting data. (Applied to new parts on Cooper programs)Level 4 - Warrant and other requirements as defined by Cooper.(Applied only with prior approval from Cooper…special situations only!)Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. (Applied to parts requiring onsite review )

YES NO

Yes No

Yes No

Yes No

Approved Rejected

Interim

Yes No

YES NO

D4

Part Name on Cooper component level print

N4

Cooper Part number on the Cooper Part Print

B5

"Yes" is so indicated on part drawing, otherwise "No"

M6

Engineering Revision level on Cooper component level print.

Q6

Located either in engineering tittle block or revision matrix on component level print. This is the date the part was revised to the most recent rev level.

F8

List all authorized engineering changes not yet incorporated on the drawing but which are incorporated in the part.

Q8

Date you were authorized to incorporate these changes.

F10

Used when the part submitted is on a different drawing then the Cooper component being submitted. The design record that specifies the customer part number being submitted.

M10

Enter this number as found on the first production release purchase order.

Q10

Enter the actual weight in kilograms to four decimal places. Must be weight of a completely finished part.

B13

Full Name of Company or Division.

G13

Supplier Vendor number as assigned by your Cooper Division

J13

Cooper Division Name Example: Cooper Wiring Devices Cooper Power Systems Cooper Lighting Cooper B-Line Cooper Bussman Cooper Krouse Hinds Cooper Safety

B15

List all locations producing the part for Cooper use.

J15

List all division manufacturing sites that use this part:

B17

Street address of either the primary site of manufacture or origin of submission.

J17

Buyer who has been your primary contact for business with Cooper.

Q17

City that Buyer's office is located in.

L20

Please state the ORIGINAL date requested by your buyer representative.

Q20

Estimated start of Cooper production or first Cooper production release due date.

Q23

Please add the PO # that matches both the part and the revision level being submitted.

Q25

List the controlled or restricted substance contained in this part. Please attach additional list or information if required.

Q26

Please record the IMDS number associated with your submission to the MDS Website.

F29

Check the appropriate box. Add explanatory details in the "other" section

H36

Identify the submission level requested by your customer and that you are submitting to.

F43

Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data if included in the submission. Level 3, 4 and 5 submissions typically require all sections.

J46

Please provide details on the number of molds. cavities or production processes within the overall production of the part reflected on the submission.

Q51

Must provide specific detail on the number of parts produced in a given window of time and the date the run was produced.

F54

Provide any explanatory details on the submission results, additional information may be attached as appropriate. Be sure to clearly state any known deviations.

D59

Name of individual responsible for preparing the part submission.

F61

The responsible supplier official, after verifying that the results show conformance to all customer requirements and that all required documentation is available shall approve the declaration and provide title, phone number, fax number and email address.

R63

This section is for Cooper approval only!!

R68

This section is for Cooper approval only!!

Note: All part print CTQ's must be clearly identified on this control plan. of 26

Control PlanControl Plan Number Key Contact / Phone Date (Orig.) Current Release Level Current Release Date

Part Number/ Latest Change (Rev) Level Part Description Supplier Code Plant Location

Core Team Supplier Name Quality Department Approval

Customer Engineering Approval / Date (If Req'd) Supplier Plant Approval Other Approval / Date (If Req'd)

CHARACTERISTICSMETHODS

CONTROL METHOD REACTION PLAN

SAMPLE

NO. PRODUCT PROCESS SIZE

FREQ

PAR

T /

PRO

CES

S NU

MB

ER PROCESS NAME / OPERATION

DESCRIPTION

MACHINE DEVICES / JIG / TOOLS FOR

MANUFACTURING

SPECIAL CHAR. CLASS

PRODUCT / PROCESS / SPECIFICATION /

TOLERANCE

EVALUATION/MEASUREMENT

TECHNIQUE

Prototype

Pre-Launch

Production

A4

This is the internal document number used to track and control the Control Plan.

D4

This is the key quality person responsible for developing and leading the control plan strategy.

H4

This is the date of original release of the control plan for the part number.

I4

This is the Revision level of the most current CONTROL PLAN release.

L4

Date the current control plan was released or became effective.

A6

Enter the part number and the most current revision level.

E6

Enter the description of the part on the Cooper print.

I6

Supplier code assigned by Cooper division you are supplying.

L6

Location of the current plant.

A8

List all key team members involved in the process and the control plan. List names, numbers and other contact information.

F8

Full Name of Supplier

I8

Signature of author or quality approval of control plan.

A10

Customer or Cooper Engineering approval (if required)

F10

Supplier Management signature of the control plan indicating executive level approval of the control plan.

I10

Any additional approvals required.

A12

The item number is usually referenced from the process flow chart. If multiple part numbers exist (assembly) list the individual part numbers and their processes accordingly.

B12

All steps in the manufacturing of a system, subsystem or component are described. Identify the process/operation that best describes the activity on each line.

C12

For each operation that is described, identify the processing equipment, machine, device, jig or other tool for manufacturing as appropriate.

D12

A distinguishing feature, dimension or property of a process or it's output on which variable or attribute data can be collected.

G12

Use the appropriate characteristic as defined by the Cooper Division you are supplying.

H12

Systematic plan for controlling a process.

L12

Brief description of how the operation will be controlled, including procedure numbers where applicable. Should be based on effective analysis of the process. Various methods can be used from additional inspection to SPC or error proofing. The method of control should be clinically evaluated for effectiveness of process control.

M12

The reaction plan specifies the corrective actions necessary to avoid producing nonconforming products or operating out of control. The actions should normally be the responsibility of the people closest to the process.

H13

Specification/tolerance may be obtained from various engineering documents such as drawings, specifications etc..

I13

Measurement system being used to check the specification or tolerance. This could include gages, fixtures, tools and or test equipment required to measure the part/process/manufacturing equipment. A measurement system analysis should be done to ensure control of monitoring and measuring devices prior to relying on a measurement system.

J13

When sampling is required list the corresponding sample size and frequency.

D14

Cross reference number from all applicable documents such as FMEAS, process flows etc..

E14

Product characteristics are the features or properties of a part that are described on the drawings or other primary engineering information. The Core Team should identify the special Product Characteristics from all sources. All special characteristics should be listed on the Control Plan.

F14

Process Characteristics are the process variables that have a cause and effect relationship with the identified Product Characteristic. A Process Characteristic can only be measured at the time it occurs. The Core Team should identify Process Characteristics for which variation must be controlled to minimize variation. There could be one or more Process Characteristics listed for each Product Characteristic. In some processes one Process Characteristic may affect several Product Characteristics.

of 26

Print # Design Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Item

Num

ber

Requirements

Current Product Controls Action Results

Prevention Detection Actions Taken

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Potential Failure Modes and Effects AnalysisDesign FMEA

Please indicate EITHER: 1.) A designated RPN threshold for this process 2.) A target percentage of steps to be addressed. Check One

Item/Function

Potential Failure Mode

Potential Effects of Failure

SEV

Class

Potential Cause(s)/Failure Mechanisms

OCC

DET

RPN

RecommendedAction(s)

Responsibility and

Completion Date

SEV

OCC

DET

RPN

N1

Either a target percentage or RPN threshold is determined by the organization owning the product. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, with a specific product your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the DFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1

Number for either percentage or threshold.

C4

Cooper Part Number as stated on Cooper Print.

I4

Department group or supplier name responsible for the item.

P4

Insert FMEA Document Number

C5

Name of the System or component for which the process is being analyzed.

I5

Phone number or email of person responsible for completing Information.

P5

Company and person responsible for preparing DFMEA

C6

Most recent revision off of Cooper Print

I6

Enter the initial due date of the DFMEA which should not exceed start of production.

P6

Enter the date the original DFMEA was completed.

C7

Identify the Core Team members for the PFMEA activity.

M7

Indicate the location city and state of the Cooper manufacturing facility that you are providing parts to.

P7

Insert date of latest revision to DFMEA

A9

The item number is may be referenced from the process flow chart or control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B9

Enter a description of each item number here.

C9

Enter the requirements of each item/function being analyzed.

D9

In what ways might the product/function potentially fail to meet the part requirements and/or funtion intent? List each potential failure mode. There can be multiple failure modes for each process step.

E9

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user. Typical failure should be stated in terms of part performance.

F9

SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK Failure to meet safety Potential failure mode affects safe product operation 10 and/or regulatory and/or involves noncompliance with regulation WITHOUT warning. requirements noncompliance with regulation Potential failure mode affects safe product operation 9 and/or involves noncompliance with warning. Loss or degradation Loss of primary function(product inoperable/does not 8 of primary function. affect safe operation). Degradation of primary function (product operable but 7 at a reduced level of performance). Loss of degradation Loss of secondary function (product operable but comfort 6 of secondary function. convenience functions at a level. Degradation of secondary function (product operable, 5 but comfort convenience functions at a reduced level of performance. Annoyance Appearance or minor issue, product operable, 4 product does not conform and noticed by most customers (>75%). Appearance or minor issue, product does not conform, 3 and noticed by many customers(50%). Appearance or minor issue, product operable, product does not conform and noticed by discriminating customers.(<25%) 2 No effect No discernable effect. 1

G9

How Severe is the effect to the customer? Identified product characteristics!

H9

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try to identify the causes that directly impacts the failure mode, i.e., root causes.

I9

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥100 per thousand pieces ≥1 in 10 VERY HIGH 9 50 per thousand pieces 1 in 20 VERY HIGH 8 20 per thousand pieces 1 in 50 HIGH 7 10 per thousand pieces 1 in 100 HIGH 6 2 per thousand pieces 1 in 500 MODERATE 5 .5 per thousand pieces 1 in 2000 MODERATE 4 .1 per thousand pieces 1 in 10,000 MODERATE 3 .01 per thousand pieces 1 in 100,000 LOW 2 ≤.001 per thousand pieces 1 in 1000,000 LOW 1 Failure is eliminated thru preventive VERY LOW control See Chart Page 28 of PPAP Hanbook for further information.

J9

What are the existing controls and procedures (inspection and test) that either prevent failure mode from occurring or detect the failure should it occur? The preferred approach is always prevention!

L9

Estimate how well can you detect cause or failure mode. Do not automatically presume that the detection is low because the occurence is low. Assess the capability of the design controls to detect low frequecy failure modes. Rank Opportunity For Detection Liklihood of Detection by Design Control Liklihood of Detection 10 No Detection Opportunity No current design control: Cannot detect or is not analyzed Almost impossible 9 Not likely to detect at any stage. Design analysis/detection controls have a weak detection Very Remote capabilty; Virtual Analysis is Not Correlated to expected actual operating conditions. 8 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Remote launch with pass/fail testing 7 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Very Low lauch with pass/fail testing 6 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Low laucn with degradation testing. 5 Prior to design freeze Product validation prior to design freeze using pass/fail testing Moderate (reliabilty testing development or validation tests). 4 Prior to design freeze Product validation prior to design freeze using test to failure Moderately High (reliabilty testing development or validation tests) 3 Prior to design freeze Product validation prior to design freeze using degradation testing High (Reliabilty testing development or validation tests). will detect error and prevent processing 2 Virtual Analysis Correlated Design analysis/detection controls have a strong detection capabilty. Very High , Virtual analysis is highly correlated with actual or expected condition prior to a design freeze. 1 Detection not applicable; Error prevention as a result of product Almost Certain Failure prevention. Failure mode cannot occur because it is fully prevented through design solutions (proven design standards, best practice or common material).

M9

SEV x OCC x DET

N9

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Prevention actions are preferable to detection actions.

O9

Enter the name of the person who is responsible for the recommended action and the target date for completion.

J10

Eliminate the cause of the mechanism of failure from occuring or reduce its occurrence.

K10

Identify the existence of a cause, the resulting mechanism of failure either by analytical or physical methods before the item is released for production

P10

List the completed actions that are included in the recalculated RPN. Include the implementation date for any changes.

Q10

What is the new severity based on the action applied.

R10

What is the new Occurrence numbers based on the action taken.

S10

What is the new detection ranking based on the action taken. Has the detection improved?

T10

Recompute RPN after actions are complete.

of 26

Print # Design Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Item

Num

ber

Requirements

Current Product Controls Action Results


Potential Failure Modes and Effects AnalysisDesign FMEA


Item/Function



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

0 0

0 0

0 0

N1

Either a target percentage or RPN threshold is determined by the organization owning the product. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, with a specific product your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the DFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1


C4


I4

Department group or supplier name responsible for the item.

P4

Insert FMEA Document Number

C5


I5


P5

Company and person responsible for preparing DFMEA

C6


I6

Enter the initial due date of the DFMEA which should not exceed start of production.

P6

Enter the date the original DFMEA was completed.

C7


M7


P7

Insert date of latest revision to DFMEA

A9

The item number is may be referenced from the process flow chart or control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B9

Enter a description of each item number here.

C9

Enter the requirements of each item/function being analyzed.

D9

In what ways might the product/function potentially fail to meet the part requirements and/or funtion intent? List each potential failure mode. There can be multiple failure modes for each process step.

E9

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user. Typical failure should be stated in terms of part performance.

F9

SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK Failure to meet safety Potential failure mode affects safe product operation 10 and/or regulatory and/or involves noncompliance with regulation WITHOUT warning. requirements noncompliance with regulation Potential failure mode affects safe product operation 9 and/or involves noncompliance with warning. Loss or degradation Loss of primary function(product inoperable/does not 8 of primary function. affect safe operation). Degradation of primary function (product operable but 7 at a reduced level of performance). Loss of degradation Loss of secondary function (product operable but comfort 6 of secondary function. convenience functions at a level. Degradation of secondary function (product operable, 5 but comfort convenience functions at a reduced level of performance. Annoyance Appearance or minor issue, product operable, 4 product does not conform and noticed by most customers (>75%). Appearance or minor issue, product does not conform, 3 and noticed by many customers(50%). Appearance or minor issue, product operable, product does not conform and noticed by discriminating customers.(<25%) 2 No effect No discernable effect. 1

G9

How Severe is the effect to the customer? Identified product characteristics!

H9

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try to identify the causes that directly impacts the failure mode, i.e., root causes.

I9

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥100 per thousand pieces ≥1 in 10 VERY HIGH 9 50 per thousand pieces 1 in 20 VERY HIGH 8 20 per thousand pieces 1 in 50 HIGH 7 10 per thousand pieces 1 in 100 HIGH 6 2 per thousand pieces 1 in 500 MODERATE 5 .5 per thousand pieces 1 in 2000 MODERATE 4 .1 per thousand pieces 1 in 10,000 MODERATE 3 .01 per thousand pieces 1 in 100,000 LOW 2 ≤.001 per thousand pieces 1 in 1000,000 LOW 1 Failure is eliminated thru preventive VERY LOW control See Chart Page 28 of PPAP Hanbook for further information.

J9


L9

Estimate how well can you detect cause or failure mode. Do not automatically presume that the detection is low because the occurence is low. Assess the capability of the design controls to detect low frequecy failure modes. Rank Opportunity For Detection Liklihood of Detection by Design Control Liklihood of Detection 10 No Detection Opportunity No current design control: Cannot detect or is not analyzed Almost impossible 9 Not likely to detect at any stage. Design analysis/detection controls have a weak detection Very Remote capabilty; Virtual Analysis is Not Correlated to expected actual operating conditions. 8 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Remote launch with pass/fail testing 7 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Very Low lauch with pass/fail testing 6 Post design freeze and prior to launch Product verification/validation after design freeze and prior to Low laucn with degradation testing. 5 Prior to design freeze Product validation prior to design freeze using pass/fail testing Moderate (reliabilty testing development or validation tests). 4 Prior to design freeze Product validation prior to design freeze using test to failure Moderately High (reliabilty testing development or validation tests) 3 Prior to design freeze Product validation prior to design freeze using degradation testing High (Reliabilty testing development or validation tests). will detect error and prevent processing 2 Virtual Analysis Correlated Design analysis/detection controls have a strong detection capabilty. Very High , Virtual analysis is highly correlated with actual or expected condition prior to a design freeze. 1 Detection not applicable; Error prevention as a result of product Almost Certain Failure prevention. Failure mode cannot occur because it is fully prevented through design solutions (proven design standards, best practice or common material).

M9

SEV x OCC x DET

N9

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Prevention actions are preferable to detection actions.

O9

Enter the name of the person who is responsible for the recommended action and the target date for completion.

J10

Eliminate the cause of the mechanism of failure from occuring or reduce its occurrence.

K10

Identify the existence of a cause, the resulting mechanism of failure either by analytical or physical methods before the item is released for production

P10


Q10


R10


S10


T10


of 26

Print # Process Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Pro

cess

Num

ber

Requirements

Current Process Controls Action Results


0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Potential Failure Modes and Effects AnalysisProcess FMEA


Process/StepFunction



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

N1

Either a target percentage or RPN threshold is determined by the organization owning the process. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, in a specific process your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the PFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1


C3


I3

Department group or supplier name responsible for the process.

P3

Insert PFMEA Document Number

C4


I4


P4

Company and person responsible for preparing PFMEA

C5


I5

Enter the initial due date of the PFMEA which should not exceed start of production.

P5

Enter the date the original PFMEA was compiled.

C6


I6


P6

Insert date of latest revision to PFMEA

A8

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B8

List the process function that corresponds to each process step or operation being analyzed. .

C8

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D8

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E8

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

F8

How Severe is the Effect on the Product SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK EFFECT SEVERITY OF EFFECT ON THE PROCESS Failure to meet safety Potential failure mode affects safe product operation 10 Failure to meet Safety May endanger operator (machine/assembly) without warning and/or regulatory and/or involves noncompliance with regulatory standards. Safety and/or regulatory requirements requirments. Potential failure mode affects safe product operation 9 May endanger operator(machine/assembly) without warning and/or involves noncompliance with regulatory standards Loss or degradation Loss of primary function (product inoperable, does not 8 Major Disruption 100% of product may have to be scrapped. Line shutdown of primary function affect safe prodyct operation). or stop shipment. Degradation of primary function (product inoperable, 7 Significant Disruption A portion of production run may have to be scrapped. Deviation but at a reduced level of performance.) from primary process including decreased line speed or added manpower. Loss or degradtion Loss of secondary function(product operable, but 6 Moderate Disruption 100% of production run may have to be reworked off line and of secondary function comfort/convience functions at a reduced level of performance. accepted. Degradation of secondary function (product inoperable, but 5 A portion of the production run may have to be reworked comfort/convience functions at a reducted level. offline and accepted. Annoyance Appearance, noise or minor issue, product operable, item does 4 100% of production run may have to be reworked in station not conform and noticed by most customers (>75%) before it is processed. Appearance, noise or minor issue, product does not conform, 3 A portion of the production run may have to be reworked and noticed by many customers (50%). in station before it is processed. Appearance, noise or minor issue, product does not conform 2 Minor Disruption Slight inconvenience to process, operation or operator and noticed by many customers (<25%). No effect No discernable effect 1 No Effect No discernible effect

G8

How Severe is the effect to the customer? Identified product or process characteristics!

H8

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

I8

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥ 100 per thousand pieces VERY HIGH 9 ≥ 50 per thousand pieces HIGH 8 ≥ 20 per thousand pieces HIGH 7 ≥ 10 per thousand pieces HIGH 6 ≥ 2 per thousand pieces MODERATE 5 ≥ .5 per thousand pieces MODERATE 4 ≥ .1 per thousand pieces MODERATE 3 ≥ .01 per thousand pieces LOW 2 ≥ .001 per thousand pieces LOW 1 Failure is elimenated through preventative control VERY LOW

J8


L8

How well can you detect cause or failure mode? RATING CRITERIA Suggested Detection Methods Detection Types 10 No Detection Opportunity Cannot detect or is not checked ALMOST IMPOSSIBLE Manual 9 Not likely to detect at any stage. Error not easily detected indirect VERY REMOTE Manual or random checks. 8 Problem detection post processing Detection by visual/tactile/audible means. REMOTE Manual 7 Problem Detection at Source Attribute Gauging/Post Processing-or Visual VERY LOW Manual 6 Problem Detection Post Processing Control is achieved with charting (SPC) LOW Gauging,Manual 5 Problem Detection at Source Detection is based on 100% gauging on set up MODERATE Gauging Performed on set-up of first piece check up 4 Problem Detection at Post Processing Detection Post Processing that will lock MODERATELY HIGH Error Proof,Gauging part from further processing 3 Pronblem Detection at Source Error detection in station or in HIGH Error Proof, Gauging will detect error and prevent processing 2 Error Detection Problem Prevention Detection in station by controls VERY HIGH Error Proof, that will prevent part from being made 1 Detection not applicable; Error prevention as a result of product . ALMOST CERTAIN Error Proof design. Item has been error proofed.

M8

SEV x OCC x DET

N8

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O8

Who is responsible for the recommended action? What is the target completion date.

J9

List the methods used that eliminate or prevent the cause of failure.

K9

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P9


Q9


R9


S9


T9


of 26

Print # Process Responsibility FMEA NumberItem Name Contact Number Prepared ByRev # Key Date FMEA Date (Orig.)Core Team Customer Manufacturing Site FMEA Date

Pro

cess

Num

ber

Requirements

Current Process Controls Action Results


Potential Failure Modes and Effects AnalysisProcess FMEA


Process/StepFunction



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

0 0

0 0

0 0

0 0

N1

Either a target percentage or RPN threshold is determined by the organization owning the process. A "target percentage" means that regardless of the RPN number, your organization will address a percentage of the highest RPN line item steps in the process WITH ADDITIONAL ACTIONS to reduce overall risk. For example, in a specific process your internal target percentage is to address the top 25% highest RPN values with additional action. This is the Cooper recommended way to address overall risk because it drives improvement regardless of RPN value. Some organizations designate an "RPN threshold" or cutoff value. This means that you will take action beyond a certain value. For example if your RPN threshold value is 50, then any items in the PFMEA that have a calculated RPN at 50 or higher require the "actions taken" section to addressed. Note: Special attention should always be given to any severity 9 or 10 items.

Q1


C3


I3

Department group or supplier name responsible for the process.

P3

Insert PFMEA Document Number

C4


I4


P4

Company and person responsible for preparing PFMEA

C5


I5

Enter the initial due date of the PFMEA which should not exceed start of production.

P5

Enter the date the original PFMEA was compiled.

C6


I6


P6

Insert date of latest revision to PFMEA

A8

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B8

List the process function that corresponds to each process step or operation being analyzed. .

C8

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D8

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E8

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

F8

How Severe is the Effect on the Product SEVERITY EFFECT SEVERITY OF EFFECT ON PRODUCT RANK EFFECT SEVERITY OF EFFECT ON THE PROCESS Failure to meet safety Potential failure mode affects safe product operation 10 Failure to meet Safety May endanger operator (machine/assembly) without warning and/or regulatory and/or involves noncompliance with regulatory standards. Safety and/or regulatory requirements requirments. Potential failure mode affects safe product operation 9 May endanger operator(machine/assembly) without warning and/or involves noncompliance with regulatory standards Loss or degradation Loss of primary function (product inoperable, does not 8 Major Disruption 100% of product may have to be scrapped. Line shutdown of primary function affect safe prodyct operation). or stop shipment. Degradation of primary function (product inoperable, 7 Significant Disruption A portion of production run may have to be scrapped. Deviation but at a reduced level of performance.) from primary process including decreased line speed or added manpower. Loss or degradtion Loss of secondary function(product operable, but 6 Moderate Disruption 100% of production run may have to be reworked off line and of secondary function comfort/convience functions at a reduced level of performance. accepted. Degradation of secondary function (product inoperable, but 5 A portion of the production run may have to be reworked comfort/convience functions at a reducted level. offline and accepted. Annoyance Appearance, noise or minor issue, product operable, item does 4 100% of production run may have to be reworked in station not conform and noticed by most customers (>75%) before it is processed. Appearance, noise or minor issue, product does not conform, 3 A portion of the production run may have to be reworked and noticed by many customers (50%). in station before it is processed. Appearance, noise or minor issue, product does not conform 2 Minor Disruption Slight inconvenience to process, operation or operator and noticed by many customers (<25%). No effect No discernable effect 1 No Effect No discernible effect

G8

How Severe is the effect to the customer? Identified product or process characteristics!

H8

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

I8

How often does the cause or failure mode occur? RATING LIKELIHOOD OF OCCURRENCE LABEL 10 ≥ 100 per thousand pieces VERY HIGH 9 ≥ 50 per thousand pieces HIGH 8 ≥ 20 per thousand pieces HIGH 7 ≥ 10 per thousand pieces HIGH 6 ≥ 2 per thousand pieces MODERATE 5 ≥ .5 per thousand pieces MODERATE 4 ≥ .1 per thousand pieces MODERATE 3 ≥ .01 per thousand pieces LOW 2 ≥ .001 per thousand pieces LOW 1 Failure is elimenated through preventative control VERY LOW

J8


L8

How well can you detect cause or failure mode? RATING CRITERIA Suggested Detection Methods Detection Types 10 No Detection Opportunity Cannot detect or is not checked ALMOST IMPOSSIBLE Manual 9 Not likely to detect at any stage. Error not easily detected indirect VERY REMOTE Manual or random checks. 8 Problem detection post processing Detection by visual/tactile/audible means. REMOTE Manual 7 Problem Detection at Source Attribute Gauging/Post Processing-or Visual VERY LOW Manual 6 Problem Detection Post Processing Control is achieved with charting (SPC) LOW Gauging,Manual 5 Problem Detection at Source Detection is based on 100% gauging on set up MODERATE Gauging Performed on set-up of first piece check up 4 Problem Detection at Post Processing Detection Post Processing that will lock MODERATELY HIGH Error Proof,Gauging part from further processing 3 Pronblem Detection at Source Error detection in station or in HIGH Error Proof, Gauging will detect error and prevent processing 2 Error Detection Problem Prevention Detection in station by controls VERY HIGH Error Proof, that will prevent part from being made 1 Detection not applicable; Error prevention as a result of product . ALMOST CERTAIN Error Proof design. Item has been error proofed.

M8

SEV x OCC x DET

N8

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O8

Who is responsible for the recommended action? What is the target completion date.

J9

List the methods used that eliminate or prevent the cause of failure.

K9

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P9


Q9


R9


S9


T9


Date of Measurement

Page #: ofSupplier Name:

Reason for Data Submission (check all that apply): Supplier Representative: Supplier Signature

Part Name: New/revised item, material or product component Name Title

Part Number Correction of Non-conformance New Supplier Judgement Legend

Drawing Number: New/Revised drawing or other specification New or significantly modified process or routing Phone Number Email: OK Meets Requirements

Revision Level: Change to optional construction or material Change of location, sub-supplier or material OKNI OK But Needs Improvement

Revision Date: Tooling: Transfer, replacement, refurbishment Other - please specify Date: Supplier Code: NG Does Not Meet Requirements

ITEM

#

Min MaxData for Sample Number…..

Average Range

JudgementComments/Action Plan

1 2 3 4 5 6 7 8 9 10 Supplier

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

NOTE: Any out of specification data will require corrective action.

DIMENSIONAL DATA SHEET

Initial submission

or additional tool.

Requ

ired

Cp

k (Y

/N)

Dat

a Ty

pe:

V=

Vari

able

A=

Attr

ibut

e REQUIREMENT:Description of Check

Measurement Method

REQUIREMENT:Target

Bonus Applied

(Y/N)

D3


D4

Balloon Drawing Title

G4

Indicate the reason that the data is being submitted. There may be more than one reason.

O4

Name of Person Completing Report

S4

Title of Person Completing Report

W4

Signature of Supplier Representative

D5

Cooper Part number on the Cooper Part Print

D6

Drawing Number and Revision listed on accompanying balloon drawing

P6

Best Number to Reach Supplier Representative

S6

Supplier Representative Email Address

D7

Revision level on Cooper component level print.:

D8

Located either in engineering title block or revision matrix on component level print. This is the date the part was revised to the most recent rev level

O8

Date Report Filled Out

T8

EFFB1:Supplier code assigned by Cooper division you are supplying

A10

Number Each Item

B10

Answer whether Cpk is required

C10

V = Variable A = Attribute

D10

Methodology

E10

Measurement system being used to check the specification or tolerance. This Could include gages, fixtures, tools and or test equipment required to measure the part/process/manufacturing equipment. A measurement system analysis should be done to ensure control of monitoring and measuring devices prior to relying on a measurement system.

F10

Nominal Dimension

G10

Indicate Y/N Whether Bonus Was Applied

H10

Minimum acceptable value

I10

Maximum acceptable value

J10

Actual Test Values

T10

Average of values entered

U10

Max less Min

X10

The Action Plan specifies the Corrective Actions necessary to avoid producing nonconforming products or operating out of control. The actions should normally be the responsibility of the people closest to the process:

V11

If test values do not fall within min and max describe corrective action here

W11

The Corrective Action Required by Cooper Industries, filled out by coordinating Cooper Industries Contact and returned to Supplier

Supplier Change Request This approved form must accompany your PPAP submission

Supplier Name Date of RequestSupplier Number Cooper Purchasing ContactSupplier Location(s) Supplier Contact Name

Supplier Contact Phone #Supplier Contact Email

Date of Proposed FUTURE Change

This section is reserved for parts sourced through CES (Cooper Electric Shaghai)CES Product? Name of CES SQE

Customer Part Number(s) Affected Customer Location(s) Affected (city,state)

Type of Change (Note:) You are required to notify and receive approval from Cooper for any of these types.(Select One) Designations in ( ) are the recommend PPAP Level submissions for this type of change

Reference: Section 3 Table 3.1 on Page 13 of AIAG PPAP 4th edition (May 2006)

ALL Information Below is to be filled out by Cooper Industries.

PurchasingTiming Plan Received Yes No Date SCR Received

Quality or Supplier QualityPPAP Required? Yes No Level Due Date

Process Audit Yes No Engineering ConsultedEngineer Date

Additional Requirements

Approval Signatures Signature Date

Purchasing Representative

Quality Representative

Supplier Information

Description of Change (Please describe in detail the nature of the change)

Customer Information: (Please list additional part numbers on a separate sheet if necessary)

1. Change to construction, material or component (L3) 7. Product/process changes on components of the product (L4) 2. New, additional or modified tools (L3) 8. Change in test or inspection method (L4) 3. Upgrade or rearrangement of existing tools (L2) 9. Bulk Material: New source of raw material (L2) 4. Tooling, production or equipment transferred to different site (L3) 10. Change in product appearance attributes (L2) 5. Change of supplier or non-equivalent materials/services (L3) 11. Change in production process or method (L4) 6. Product when tooling has been inactive for 12 months (L2) 12. Change of Sub Supplier or material source (L3)

Cooper Requirements (Plant Quality, Supplier Quality and Puchasing)

Mandatory Distribution: Plant Operations, Plant Quality, Purchasing, Supplier Quality and Engineering

Yes No

D5


K5

This is the date you are sending this request to Cooper

D6

Supplier Code assigned by Cooper Industries

K6

This is the name of the Cooper purchasing representative that you work with.

D7

List all locations affected by this proposed change.

K7

This is the person that should be contacted at your organization for questions concerning this change.

G11

This is the proposed date that the change would become effective once you have received approval from Cooper.

C14

This is a detailed explanation of the change and the reasons why is is important for your organization.

D20

This question is for products sourced through CES ONLY!

J20

This is the name of the designated ASC SQE or SD representative.

C23

List all affected part numbers…attach additional list if neccessary

I23

List all Cooper Manufacturing sites affected by this change.

A30

These are all of the specific types of changes that Cooper requires approval for prior to implementation. If you are not sure the proposed change you are planning falls into one of these types, contact your Cooper Purchasing repesentative.

of 26

Tooling Information Form XXXXX

Supplier Name PPAP Submission Level Affected Feature Number(s) Part Description

Date PPAP Due Date Part Number Tool LocationFacility

Date of Tooling Change Part Name MachineStation

New Tooling Modified Tooling Required for PPAP Note: This document must be completed for all Cooper owned tooling.

Complete Supplier Tooling Action Item List to ensure all items are completed.

TOOLING ACTION ITEMS Who What When StatusTooling ImagesDiagram or Strip LayoutTool DrawingsTool Cost Breakdown

Design CostMaterial Cost

Labor CostTool DescriptionTool Dimensions

LengthWidth

HeightDaylight Opening

WeightPress SizeTool MaterialTool Capacity

HourlyDaily

AnnualLife Expectancy

Comments

Cooper Tooling reference number. (if applicable)

N1

This number is provided by purchasing and must be included with this document and attched or engraved into the cooper owned tool. This reference number should also be included with the tool tag pictures.

A3

Supplier Name providing part to Cooper (Not Tool Maker)

D3

This is Level 1-5 based on what Cooper Quality or Supplier Quality has requested.

G3

CHANGES ONLY! If submiiting this document for a change to an exisiting tool, please reference which dimensions are affected by listing the Balloon numbers off of the dimensional report.

J3

Should include information such as the part number, tool information, number of cavities etc..

A5

Date dcoument created.

B5

Date PPAP is due.

D5

Actual PO Part number off of Cooper part print.

H5

Manufacturing Facility

H6

Internal machine reference number(s)

A7

Changes Only! This is the actual date a modified tool ran production product.

D7

As listed on the Cooper Part Print.

H7

Internal Station number if applicable.

D11

List responsible individual in your organization.

G11

List actual values and activities for each item.

J11

Due date for when the item is to be completed.

L11

Status of each item which should be complete at the time of PPAP submission. Date complted should also be included.

A12

Provide images of the tool from all sides and show Cooper owned tooling information if applicable.

A13

This is based on your own internal procedures.

A14

Person responsible for drawings the CAD drawing format the files are created in.

A15

Identify responsible person for costing and list all requested costs. These cost must be consistent with your accepted quote to Cooper.

A19

Brieif description of the tool.

A20

Identify the responsible person for all dimensions and all applicable dimensions.

A26

Identify the press (if applicable) that this tool is scheduled to run on.

A27

Identify the person responsible for developing the tool and the material grade. If this is an outsouce vendor then please list who the vendor is and the primary contact person.

A28

What is the planed capacity for this tool based on your quoted volumes to Cooper.

A32

Life expectancy of tooling as measured in MAXIMUM number of parts produced before discarding.

of 26







Fig. 1 Top View Fig. 2 Bottom View

Fig. 3 Left View Fig. 4 Right View

N1


A3


D3


G3


J3


A5


B5

Date PPAP is due.

D5


H5


H6


A7


D7


H7


B42

Paste digital images into cell. Resize as appropriate. Accepted formats include JPG and TIFF. Maximum width is 4" (100mm), maximum height is 2.25" (57mm)

H42


B57


H57


of 26







Fig. 5 Front View Fig. 6 Back View

Fig. 7 Tool Tag View Fig. 8 Example

N1


A3


D3


G3


J3


A5


B5

Date PPAP is due.

D5


H5


H6


A7


D7


H7


B72


H72


B87


of 26







Additional Comments

N1


A3


D3


G3


J3


A5


B5

Date PPAP is due.

D5


H5


H6


A7


D7


H7


Packaging FormDate Packaging Contact Part Number Supplier Responsibilities Completed?

Packaging DesignSupplier Name Phone Number Print Revision Level

Supplier Code Fax Number Part Description

Supplier Production Facility E-Mail Address HAZMAT?

DIG

ITA

L IM

AG

ES

Part In Packaging Position Container With Label Shown

PAC

KA

GE

DA

TA

Component L (mm) W (mm) H (mm) Component Wt (kg) QuantitiesPart Size Part Qty Parts per Container

Container Only Dunnage (Tare) Container(s) per Layer on PalletPallet Only Container (Tare) Later per Pallet

Unit Load As Shipped Pallet (Tare) Container(s) per PalletIn to MM Lbs to Kg Container Gross (Inc Parts) Stacking Rule

0 0 Unit Load Gross (Inc Parts)

Packaging that prevents shipping and material handling defects

Electronic storage of submitted Packaging Data Form

Yes No

J2

Refer to PPAP handbook for divisional specific packaging and testing requirements.

A3

Date packaging design and this document are complete

D3

Overall person responsible for packaging in the event Cooper has a concern or labeling question.

G3

Part number as it appears on the the Cooper Part Print.

A5

Supplier Name

D5

Supplier Phone Number.

G5

Revision Level as identified on the Cooper Part Print.

A7

SAP supplier code

D7

Fax number or email address for Supplier

G7

Description as it appears on the Cooper Part Print.

D9

Email address for the Packaging Contact.

I9

Please identiy any Hazmat products or packaging materials







Yes No

DIG

ITA

L IM

AG

ES

Dunnage In Container Position Unit Load As Shipped With Label Shown

Description Manufacturer Material Lead Time RET/EXP COMMENTSDunnageContainer ColorContainer TypeCover/Top CapPalletStretch/Shrink FilmBanding

PAC

KA

GIN

G

MA

TER

IALS

J2


A3


D3


G3


A5

Supplier Name

D5


G5


A7

SAP supplier code

D7


G7


D9


I9








Yes NoOther

PAC

KA

GIN

G

MA

TER

IALS

J2


A3


D3


G3


A5

Supplier Name

D5


G5


A7

SAP supplier code

D7


G7


D9


I9


Specification Deviation FormExisting Production Deviation PPAP Submission Check Here to Request Print Changes

Part Name Part No: Expiration Date

Drawing or Spec No. Revision Revision Date

Purchase order number Initiated By Maximum Units to be Deviated

Interim Action

Interim Action Status Effect on Cost, Quality and/or DeliveryRework

Due Date

Corrective Action(s)# Action Item Responsible Party Due Date Status

Cooper Internal Use Only- Engineering and Quality comments

Approval SignaturesRoute To Approve Reject Signature Date

Manufacturing EngineerManufacturingPurchasingProject EngineerQuality

Engineering or Quality Final Disposition Approve Reject

Requirement Stated on Drawing or Specification

Actual Observed Results or Condition

Deviation from Specification to be Allowed

Choose One

A5

Part name as stated on print.

D5


G5

Expiration date of the deviation request

A7

Drawing or specification number

D7


G7

Date revision was completed

A9

PO Number from Cooper division

D9

Name of individual requesting the deviation.

G9

Specify quantity of units allowed under the deviation.

A11

Supplier enters the nominal or target value

D11

Supplier provides data on what the process is currently producing

G11

Specific information to be provided by Cooper as to what is acceptable.

A18

Attach an additional sheet if necessary.

A19

Enter the interim action plan to improve the process.

C24

Attach additional sheet if necessary.

A25

Select status of interim action from drop down list

C25

Summary as to how the interim action will affect cost, quality and delivery

A28

Date when interim action will be completed.

A32

Action item number

B32

Specific action to improve the out of tolerance condition

F32

Person(s) responsible to complete the action item on or before the due date.

H32

Date as to when the improvement action item is completed.

I32

Update as to whether completed or delayed.

GR&R Study - Multiple Operators

Part Number: Supplier Name: DateDrawing Number: Supplier Address:

Drawing Rev.: Supplier ContactRev. Date:

Drawing Location: PCA Supplier Name: GR&R ContactPart Feature: PCA Address:

Feature Symbol: PCA ContactOther Information

Calibration Date: Gage Type: Gage ID: Unit of Measure:

Operator 1 Name Operator 2 Name Operator 3 Name

0 0 0USL LSL Number of Trials: Number of Operators:

Operator 1 Operator 2 Operator 3Part # 1st Trial 2nd Trial 3rd Trial Range 1st Trial 2nd Trial 3rd Trial Range 1st Trial 2nd Trial 3rd Trial Range

1 Error Error Error2 Error Error Error3 Error Error Error4 Error Error Error5 Error Error Error6 Error Error Error7 Error Error Error8 Error Error Error9 Error Error Error10 Error Error Error

* A minimum of six samples for each trial is required for these results to be valid

Gage R&R Summary Gage R&R DispositionMeasurement Unit Analysis

Disposition #VALUE!Repeatability: EV= #VALUE!Reproducability: AV= #VALUE!

R&R= #VALUE!Part Variation: PV = #N/A

Pass - Gage System is UseableTotal Variation: TV= #VALUE!

% Process Variation (TV) / % Tolerance Variation (TOL)#VALUE! #VALUE!#VALUE! #VALUE!#VALUE! #VALUE!

Fail - Gage System is Unstable#N/A

For use with testing gage systems meant to evaluate features or processes whose output measured numerically, and for which two to three operators are expected to conduct the evaluation. Rev. 11/1/07 Dave Olson

GR&RTOL% < 10

10 ≤ GR&RTOL% ≤ 30 Gage System is useable but marginal% Equipment Variation (EVTV) %EVTOL

% Appraiser Variation (AVTV) %AVTOL

%GR&R (GR&RTV) %GR&RTOL

GR&RTOL% > 30%Part Variation (PVTV)

1 2 3 4 5 6 7 8 9 10

0.000

2.000

4.000

6.000

8.000

10.000

12.000

Part Operator AverageMost part averages should be outside the

control limits

UCLx LCLx Bar-X Op1 X Op2 XOp3 X

Ope

rato

r X

Valu

es

1 2 3 4 5 6 7 8 9 100

2

4

6

8

10

12

Repeatability Range (All Operators)

UCLr Bar-R Op1 Range Op2 RangeOp3 Range

Sample Number

Bar

R

D5

Part number as it appears on the Cooper Part Print.

H5

Full name of supplier

D6

Drawing number listed on balloon drawing.

H6

Enter supplier address

J6

Enter the date(s) the data was compiled

D7

Most recent revision number taken from Cooper print.

D8

Date revision was completed

J8

Contact representative at Supplier

D9

Grid Location

H9

Process Capability Analysis supplier name

D10

Specific Call Out

H10

Process Capability Analysis Supplier address

J10

Name of individual responsible for GR&R study.

D11

Identification used for the feature

D12

Add additional pertinent information

J12

Name of Process Capabilty Analysis supplier contact person

C14

Date of iInstrumentation's last calibration

F14

Enter type of gage used

I14

ID of Equipment

L14

Unit of measure used

A16

Insert the name of the first operator involved in the GR&R study.

E16

Insert the name of the second operator involved in the GR&R study.

I16

Insert the name of the third operator involved in the GR&R study.

A19

Upper Spec Level

B19

Upper Spec Limit

C19

Lower Spec Limit

E19

Enter the number of trials operators conducted

H19

Total number of operators involved in study

B22

Enter 1st trial data

C22

Enter 2nd trial data

D22

Enter 3rd trial data

E22

Output is range of operator data results

F22


G22


H22


I22


J22


K22


L22


M22


A35

Gage R&R Is the Percentage of Measurement Variation (Repeatability and Reproducibility) in the Process Under 10%: Acceptable Gage 10% to 30%: May Be Acceptable Over 30%: Unacceptable and Should Be Corrected or Replaced

C37

Repeatability (Gage precision) The variation in measurements obtained with one gage when used several times by an operator while measuring the identical characteristic on the same part. Referred to as equipment variation in a Gage R&R study.

C38

Reproducibility (Operator precision) The variation in the average of the measurements made by different operators using the same gage when measuring a characteristic on one part. Referred to as Operator Variation in a Gage R&R Study.

C39

Repeatability and Reproductability

1 2 3 4 5 6 7 8 9 10

0.000

2.000

4.000

6.000

8.000

10.000

12.000

Part Operator AverageMost part averages should be outside the

control limits

UCLx LCLx Bar-X Op1 X Op2 XOp3 X

Ope

rato

r X

Valu

es

1 2 3 4 5 6 7 8 9 100

2

4

6

8

10

12

Repeatability Range (All Operators)

UCLr Bar-R Op1 Range Op2 RangeOp3 Range

Sample Number

Bar

R

Process Capability Analysis - Ppk

Are the Design Characteristics Safety Related, or Functional?



Drawing Location: PCA Supplier Name:Part Feature: PCA Address:

Feature Symbol:Other Information

Limits PCA SummaryUSL Process Data Potential Capability

LSL LSL = 0.000 Error in STDEVUSL = 0.000 Error in STDEV

Mean = No Data Ppk = Error in STDEVTest Data StDev = 0.000 Pp = Error in STDEV

Test No. Test %Cr = Error in STDEV1 Max = 0.0002 Min = 0.0003

4 Spec Frequency

5 1 0.000 #VALUE!6 2 0.000 #VALUE!7 3 0.000 #VALUE!8 4 0.000 #VALUE!9 5 0.000 #VALUE!

10 6 0.000 #VALUE!11 7 0.000 #VALUE!12 8 0.000 #VALUE!13 9 0.000 #VALUE!14 10 0.000 #VALUE!15

16

17

18

19

20

21

22 Disposition Invalid PPK

23 Ppk < 1.33 Reject, Corrective Action Needed 24 Ppk ≥ 1.33 Accept25

Use when: (a) You are a new supplier to Cooper that has already been manufacturing the specified part, or (b) you are an existing supplier who has been found to have supplied a large number of nonconforming parts.

Ppku =

Ppkl =

0.000

0.000

0.000

0.000

0.000

0.000

0.000

0.000

0.000

Distribution

Values

Freq

uenc

y

Safety Related (Ppk ≥ 1.67) Functional (Ppk ≥ 1.33)

Cpk for Subgroups

Part Number: Supplier Name: Date of StudyDrawing Number: Supplier Address:




PCA SummarySubgroup Sizes Limits Process Data Potential Capability

30 Subgroups of Size 2 USL USL= 0.000 Cp = Error in STDEV25 Subgroups of Size 5 LSL LSL= 0.000 CpkL = Error in STDEV50 Subgroups of size 5 Mean= Error CpkU = Error in STDEV

StDevE= Error Cpk = 0.000UCLx= %Cr = Error in STDEVLCLx= Max = UCLR= Min =

Subgroup Test 1 Test 2 Test 3 Test 4 Test 5 Average Range1 0.000 Spec Frequency2 0.000 1 #VALUE!3 0.000 2 #VALUE!4 0.000 3 #VALUE!5 0.000 4 #VALUE!6 0.000 5 #VALUE!7 0.000 6 #VALUE!8 0.000 7 #VALUE!9 0.000 8 #VALUE!

10 0.000 9 #VALUE!11 0.00012 0.00013 0.00014 0.00015 0.00016 0.00017 0.00018 0.00019 0.00020 0.00021 0.00022 0.00023 0.00024 0.00025 0.000262728293031323334353637383940414243444546474849

Use when: (a) new part, (b) part with revised specifications, (c) part in which the materials, processes, manufacturing location, or production equipment have significantly changed, or (d) part in which the material suppliers have changed.

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

#VAL

UE!

Histogram

Test Values

Freq

uenc

y

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

0

2

4

6

8

10

12Averages Chart

X X-Bar LCLx UCLxSample Number

Sam

ple

Valu

e

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

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Control Chart

Range R-Bar UCLr

Sample Number

Ran

ge

50

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

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Control Chart

Range R-Bar UCLr

Sample Number

Ran

ge

Cpk for Moving Range





USL PCA SummaryLSL

Process Data Potential Capability

Subgroup Test Value Range LSL= 0 Cp=

1 USL= 0 CpkL=

2 0.00 Mean= CpkU=

3 0.00 StDev 0 Cpk= 04 0.00 UCLX= %Cr=

5 0.00 LCLX= Max= 0.00006 0.00 UCLR= 0 Min= 0.00007 0.008 0.00 Spec Frequency

9 0.00 1 0.0000 #VALUE!10 0.00 2 0.0000 #VALUE!11 0.00 3 0.0000 #VALUE!12 0.00 4 0.0000 #VALUE!13 0.00 5 0.0000 #VALUE!14 0.00 6 0.0000 #VALUE!15 0.00 7 0.0000 #VALUE!16 0.00 8 0.0000 #VALUE!17 0.0018 0.0019 0.0020 0.0021 0.0022 0.0023 0.0024 0.0025 0.0026 0.0027 0.0028 0.0029 0.0030 0.0031 0.0032 0.0033 0.0034 0.0035 0.0036 0.0037 0.0038 0.0039 0.0040 0.0041 0.0042 0.0043 0.0044 0.0045 0.0046 0.0047 0.0048 0.0049 0.0050 0.00

Average 0.00

Use when: (a) new part, (b) part with revised specifications, (c) part in which the materials, processes, manufacturing location, or production equipment have significantly changed, or (d) part in which the material suppliers have changed AND testing is too expensive to be conducted by subgroups.

1 2 3 4 5 6 7 8 9 1011 1213 141516 1718 1920 212223 2425 262728 2930 3132 333435 3637 383940 414243 4445 4647 4849500

2

4

6

8

10

12Averages

X X-Bar Upper Control Limit Lower Control LimitSample Number

Test

Val

ue

1 2 3 4 5 6 7 8 9 1011 121314 15161718192021 22232425262728 29303132333435 363738 39404142434445 46474849500

1

1Range Chart

Range UCL Range Average Moving Range AverageSample

Rang

e

0.00

00

0.00

00

0.00

00

0.00

00

0.00

00

0.00

00

0.00

00

0.00

00

Distribution

Test Values

Freq

uenc

y