AIAG
AIAG
AIAG
PPAP packages are expected to be received by Woodbridge by the date assigned by Purchasing. If for any
reason you cannot meet this date, contact Purchasing for resolution.
You may Email this file to kim_morris@woodbridgegroup.com in lieu of printing and copying.
Suppliers are expected to maintain a copy of all the latest customer specifications.
These forms have been provided as a service. If you are currently using software that meets the requirements
of the AIAG manuals listed below, they will be accepted. For further information, please see Supplier
Requirement Manual on www.woodbridgegroup.com. A PPAP checklist is also available on the Website.
When you see the red triangle in the upper right corner of a cell, move your mouse/cursor over it
and instructions will pop up. Try the cell to the left of here.
You will also see some website links that may be helpful.
Important Note: These sheets have not been protected, so you can add additional information if needed.
However, the information in blue is interlinked to the other spreadsheets. Therefore, please take into
consideration that you may destroy the interlinking capability if you change anything.
FILL IN THE BLUE SECTIONS FOR AUTOMATIC INPUT INTO FORMS
Ye N
Safety and/or Government Regulation Purchase Order No. Weight (kg)
s o
Checking Aid No. Checking Aid Engineering Change Level Dated
ADDRESS
Street Address WFC Purchasing Contact
MATERIALS REPORTING
SUBMISSION RESULTS
The results for dimensional measurements 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 Part
Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of ______ / ______
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:
Title E-mail
TRO-QUA-F-001 26-Apr-06
Supplier Team Members
Location Name Side Title
Customer
Product Name
Part No.
Part Name
Notice Level
Reference No.
4 Production
4.1 Penyiapan Material RM 1 day BKB
4.2 Proses Produksi Prod 1 day SPPr
4.3 Pengujian QC QC 1 day LPP
4.4 Delivery to CWH Prod 1 day BPB
4.5 Delivery to Customer Logistik 2 days SJ
*) As per normal, and may change due to: customer request, problem occurences, complexity of product, etc.
APQP STATUS REPORT
Nama PT. :
bers Phone / email address
Phone Email addr
Actual
23 Start Finish
1 2
Ford General Motors APPEARANCE APPROVAL REPORT
PART DRAWING APPLICATION
NUMBER NUMBER NUMBER (VEHICLES) APPLICATION
PART BUYER E/C LEVEL DATE
NAME NAME CODE ECN
ORGANIZATION MANUFACTURING ADDRESS SUPPLIER
NAME SUPPLIER Company LOCATION CITY STATE ZIP CODE CODE
REASON FOR PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION OTHER
SUBMISSION PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
APPEARANCE EVALUATION
AUTHORIZED CUSTOMER
ORGANIZATION SOURCING AND TEXTURE INFORMATION PRE-TEXTURE REPRESENTATIVE
EVALUATION SIGNATURE AND DATE
CORRECT
AND PROCEED
CORRECT AND
RESUBMIT
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
TRISTIMULUS DATA METALLIC COLOR
COLOR MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS BRILLIANCE SHIPPING PART
SUFFIX DL* Da* Db* DE* CMC NUMBER DATE TYPE SOURCE RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW SUFFIX DISPOSITION
COMMENTS:
ENGINEERING PRE-TEXTURE
CONCURRENCE
MASTERING STUDIO
POST TEXTURE
COMMENTS:
CUSTOMER INTERIM APPROVAL DATE
SIGNATURE
TRO-QUA-F-001 26-Apr-06
Page 10 of 29 Pages
ECN
NOT
OK
ults.
Page 11 of 29 Pages
ECN
NOT
OK
Production Part Approval - Page 29 of 12 Pages
TRO-QUA-F-001 26-Apr-06
Page 29 of 13 Pages
ECN
NOT
OK
st results.
Page 14 of 29 Pages
TRO-QUA-F-001 26-Apr-06
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed
0 0 0
20 R x D3* = LCLR=
* D4 =3.27 for 2 trials and 2.58 for 3 trials; D3 = 0 for up to 7 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or dis-
card values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
TRO-QUA-F-001 26-Apr-06
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characteristic Gage Type Appraiser C
All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).
K1 is 5.15/d2, where d2 is dependent on the number of trials (m) and the number if parts times the number of operators (g) which is
assumed to be greater than 15.
AV - If a negative value is calculated under the square root sign, the appraiser variation (AV) defaults to zero (0).
K2 is 5.15/d2, where d2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.
K2 is 5.15/d2, where d2 is dependent on the number of parts (m) and (g) is 1, since there is only one range calculation.
d2 is obtained from Table D3, "Quality Control and Industrial Statistics", A.J. Duncan.
GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
SHORT FORM ATTRIBUTE RESULTS
Part Number Gage Name Appraiser A
NUMBER
Part Name Gage Number Appraiser B
NAME
Characterisitic/Specification Gage Type Date Performed
APPRAISER A APPRAISER B
PART # TRIAL #1 TRIAL #2 PART # TRIAL #1 TRIAL #2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
No Reject Gage
Remarks
TRO-QUA-F-001 26-Apr-06
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # NUMBER Rev. ECN (DESIGN FMEA) FMEA Number: FILE.XLS
Item: NAME Process Responsibility: SUPPLIER Company Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Design FMEA is
Team: ✘ Date (Rev.)
attached
TRO-QUA-F-001 26-Apr-06
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # NUMBER Rev. ECN (PROCESS FMEA) FMEA Number: FILE.XLS
Item: NAME Process Responsibility: SUPPLIER Company Prepared by:
Model Year(s)/Vehicle(s) APPLICATION Key Date Date (Orig.)
Design FMEA is
Team: ✘ Date (Rev.)
attached
TRO-QUA-F-001 26-Apr-06
FMEA LISTS Table 6, Page 43: PFMEA Severity Evaluation Criteria
Third Edition Criteria: Severity of Effect Criteria: Severity of Effect
This ranking results when a potential This ranking results when a potential
failure mode results in a final failure mode results in a final
customer and/or a customer and/or a
manufacturing/assembly plant defect. manufacturing/assembly plant defect.
The final customer should always be The final customer should always be
considered first. If both occur, use the considered first. If both occur, use
higher of the two severities. the higher of the two severities.
(MANUFACTURING/ ASSEMBLY
SEVERITY SCALE (CUSTOMER EFFECT) EFFECT)
Very high severity ranking when a
potential failure mode affects safe
vehicle operation and/or involves
noncompliance with government Or may endanger operator (machine
10 Hazardous - w/o warning regulation without warning. or assembly) without warning.
Very high severity ranking when a
potential failure mode affects safe
vehicle operation and/or involves
noncompliance with government Or may endanger operator (machine
9 Hazardous - w/ warning regulation with warning. or assembly) with warning.
Or 100% of product may have to be
scrapped, or vehicle/item repaired in
Vehicle/item inoperabe (loss of repair department with a repair time
8 Very High primary function). greater than one hour.
Fit and Finish/Squeak and Rattle item Or the product may have to be
does not conform. Defect noticed by sorted, with no scrap, and a portion
4 Very Low most customers (greater than 75%). (less than 100%) reworked.
Or a portion (less than 100%) of the
Fit and Finish/Squeak and Rattle item product may have to be reworked,
does not conform. Defect noticed by with no scrap, on-line but out-of-
3 Minor 50% of customers. station.
Fit and Finish/Squeak and Rattle item Or a portion (less than 100%) of the
does not conform. Defect noticed by product may have to be reworked,
discriminating customers (less than with no scrap, on-line but out-of-
2 Very Minor 25%). station.
Or slight inconvenience to operation
1 None No discernible effect. or operator, or no effect.
OCCURRENCE SCALE
10 >/= 100/1000 pieces - Very High Persistent Failures
9 50/1000 pieces - Very High Persistent Failures
8 20/1000 pieces - High Frequent Failures
7 10/1000 pieces - High Frequent Failures
6 5/1000 pieces - Moderate Occasional Failures
5 2/1000 pieces - Moderate Occasional Failures
4 1/1000 pieces - Moderate Occasional Failures
3 .5/1000 pieces - Low Relatively Few Failures
2 .1/1000 pieces - Low Relatively Few Failures
1 </= .01/1000 pieces - Remote Failure is Unlikely
INSPECT
STORE
MOVE
PRODUCT AND
ITEM #
ITEM #
OPERATION PROCESS CONTROL
STEP DESCRIPTION CHARACTERISTICS METHODS
TRO-QUA-F-001 26-Apr-06
CONTROL PLAN
Prototype Pre-Launch ✘ Production Engineering Change Documents are attached
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
CP-P-1
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
MACHINE,
CHARACTERISTICS METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
1 Wax Melting Heater tank 1 Temperature 70 degree Celcius Thermal IR 1X every 5 Data Loger Adjusment
minutes Temperature
2 Apperance Clear liquid visual 1X end off Checklist Ikuti WI-xxx
process Data
2 Mixing Mixer 1 Speed 500 rpm +/-3% Digital 10 minutes Digital timer auto adjusment
Tacometer
2 pH 7 s/d 9 pH Meter 1x bufer Dosing auto adjusment
pump
3 Dipersi Mixer 1 Speed 1500 rpm +/- 3% Digital 10 minutes Digital timer auto adjusment
Tacometer
2 Kehalusan 15 mikron Partical size 1x Visual Auto grinding
analyzer system
4 Packging by APS 1 Weight 0.9 Kg by AWY Sepanjang Digital Reseting
proses
CONTROL PLAN
Prototype Pre-Launch ✘ Production Engineering Change Documents are attached
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
CP-P-1
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
MACHINE,
CHARACTERISTICS METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
TRO-QUA-F-001 26-Apr-06
The following items are to be included in your package:
Six parts per tool or tool cavity submitted to using plant(s) for Appearance & Functional evaluation (use pink Sample Parts
✘
Label)
✘ End of Life Vehicle (ELV) Reporting to the International Material Data System (IMDS) www.MDSystem.com
Cpk results of at least 100 data points with histogram for each special characteristic called out on the drawing, control plan or by
✘
Woodbridge.
✘ Design FMEA
✘ QS-9000/TS-16949 Certification
✘ Design Records - submit a ballooned copy of the drawing that corresponds to the Dimensional, Mateiral and Performance Results
GM Only -- Applied Paint On Plastic Approval Letter (APOPS) for painted plastic parts
WHAT ACTIONS ARE TAKING PLACE TO ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM TO
BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE?
TRO-QUA-F-001 26-Apr-06
1 SHAFT CONNECTOR 2 TUAS COUPLING / CLUTCH
TUAS COUPLING / CLUTCH LEVER