Global Supply Management
F1021_PPAP_checksheet_ instructions Revision Date: December 22, 2014
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procedure or a copy of the procedure is included. If work instructions are referred to in the
Control Plan, they should be included in the PPAP package. The Control Plan must include the
print revision number and letter and be comprehensive (i.e. it must include all part dimensional
characteristics and notes provided on the blueprint. These characteristics must be listed on the
Control Plan with the process characteristics that link to them in a cause and effect relationship).
The Control Plan must be part, or part family, specific. Sub-Supplier Control Plans should be
available for Nexteer review (if requested). Anything required to make a defect-free part needs
to be addressed in the Control Plan. Sample sizes must be defined in number of parts. Sample
frequencies must be defined as a specific quantity of parts, or as a specific time interval.
General terms such as: “Per Box”, “Each Lot”, Each Production Run”, “Each load”, etc, are not
acceptable. Important: There must be a one-to-one match of the Operation numbers between
PFD, FMEA and the Control Plan to allow for cross-referencing of the documents.
8) Measurement System Analysis (Gage R&R) – All gages in the Control Plan must have a
Gage R&R study completed. For the PPAP Submission; only Gage R&R’s for Special
Characteristics are to be submitted.
Variable Gage R&R's – Must be done and included in the PPAP submission even if the
gage is a hand tool, such as micrometers or calipers. This also includes CMM. Variable
gage studies shall be completed with all operators who will be using the gage as part of
normal production process. Studies are to be of the format: 3 operators 3 trials, using 10
parts. The 10 parts need to be representative of the process. All variable gage R&R studies
should have a minimum of 5 distinct categories. The preferred method for calculating the
gage R&R is by using the ANOVA method. Gages not meeting the acceptance criteria per
the AIAG MSA manual shall have a containment plan (such as 100% inspection, gage
improvement, or other means). Gage study records shall be maintained. The preferred tool
for reporting this data is Minitab (version 15 or newer). Additional information may be found
in section 4.10 of the Nexteer Supplier Requirements.
Attribute Gage R&R – Shall be completed with 3 operators, 3 trials, using 50 parts and
evaluated with Kappa calculations as outlined in the AIAG manual. The AQE/SQE can
provide an electronic template for this attribute study, which will streamline the gage study
method and eliminate confusion and inconsistencies with Nexteer’s expectations.
Important: If a CMM is used to complete the initial process capability study on a feature
that is checked with an attribute gage in the Control Plan, then a variable gage study must
be completed on the CMM and an attribute study on the attribute gage.
The latest version of the MSA Manual: www.aiag.org
9) Dimensional Results – Dimensional results must correspond to the “Road Mapped” or
“Ballooned” Print / Design Record Details (including any and all drawing notes). Each data point
must indicate “In Spec/Out of Spec”, and/or “Pass/Fail”. An Interim Recovery Worksheet must be
filled out by the Supplier, for any requirements not met, and signed by the Nexteer AQE/SQE
and Product Engineer. A total of 5 pieces per Value Stream are to be checked for Dimensional
Results. When reporting on the dimensional results of a True Position, and/or Profile, GD&T
requirement, also report the dimensional results for the Basic Dimensions that are associated
with the GD&T requirement. AQE/SQE is to request that the Supplier identify any bonus
tolerance resulting from MMC or LMC.
10) a) Material Certifications – Include any material certifications / material test results relating to
the part and the base materials from the Supplier’s internal lab or outside contracted lab.
Identification of the Specification and Lot of material must be identified on the Control Plan. If
there are material specifications and or purchase specifications noted on the print, you must