Issue 1

PPAPProcess

Is Item
Y es No
proprietry

ISIR Completion Inf orm supplierof HendricksonPPAP

Inf orm supplierof
Notes PPAP(Including Master
ISIR requirements.
ISIR)requirements

Rev iewPPAP
5 Parts submitted PPAP
trackingdocument
with completed requirements
and complete
documentation.
Initialissue.

Carry out regular

Select random rev iews with
sample and suppliers and
rev iew updatePPAP
trackingdocument

5 Parts rev iewed

at supplier
Is location/or
Request
No documentation submittedtoHEL
correctiv e actions
and sample OK with f ull PPAP
documentation

Y es

Select random
Enter on to index sample (1 or 2)
and KBM as andv erif y
approv ed.

Do parts and
documentationmeet HEL
Change KBM to Y es
requirements? No
status 1

Grant Interim
Correctiv eaction
approv al and
plan required f rom
input status on
supplier.
KBM

Carry out
capability studies
on all Signif icant
Charateristics

Enter on to index
and KBM as
approv ed.

Change KBM to
status 1

PPAP.xls Page 1
Issue 1

Current PPAP requirements

5 samples complete with an dimensional report for each top level and lower level parts.
Samples are identified against the PPAP report so that the actual measurement can be compared to supplier’s results.
Complete with the Dimensional Sheet's will be the raw material certificate clearly showing the specification and results of the material assessment, and all post treatment certificates complete with supporting documentation.
PFMEA, Control Plan, Process Flow, and signed PSW front sheet will be required in addition to the dimensional and material requirements.

PPAP reports

Everything on the drawing must be reported in the PPAP this includes all dimensions/features/notes. Any certificates that are supplied must also be reported on the ISIR using unique identification (and grid ref on the drg) to ensure an audit trail.
All dimensions reported will indicate the maximum and minimum sizes assessed/measured.
All the boxes should be completed in line with the ‘notes’ affixed at the end of the "Dimensional Front Sheet" blank.
The X in the Dim box on the Dimensional Front Sheet is to confirm that the PPAP has been reviewed and all the dimensions/features/notes/have been reported. X in the Mat’l box indicates that material and/or post treatment certificates are attached.

Omissions/errors that will cause the PPAP to be rejected.

Delta symbol characteristic(s) missed

Omission of geometrical feature(s)
Omission of a number of features that cannot be verified by HEL
Incorrect issue level/ECN number
Omission of the appropriate certificates and/or supporting documentation.
Errors in data entry reporting, typing errors that result in an incorrect reported result. (Need to have all copies of the ISIR the same in case of sub-sub auditing by customer).

Validation Process Carried out by HEL

Top-level component is measured and as a minimum all delta symbol denoted characteristics and all geometrical features are assessed and all features that have an impact on interchangeably. Additional attributes depending on history and current known complaints.

The documentation package is audited to ensure compliance and any concerns/issues are advised to the supplier in documentary form. When the item is approved the ISIR(s) is duly authorised after the entry of dimensions/features/notes assessed.

At the time of assessing the top level all the lower level parts are reviewed for all delta features that are not impacted by the conclusion of the assembly. The PPAP reports audited and sentenced accordingly.

~5175854.xls Page 1
Issue 1

HENDRICKSON PPAP LEVEL 3 EXPECTATIONS

1 Copy of Drawing Dimensions numbered & referenced on

2 Feasibility Commitment
3 Process Capacity Sign Off
4a Dimensional Reports for 5 Samples
4b Material Certificates / Reports
4c X-ray Reports on the 5 samples
4d Paint Compliance Report
4e Material Performance Data
5 Process Flow Chart
6 PFMEA or PFMEA Summary
7 Production Control Plan
dimensional report.
Agreement between HEL & Supplier
Esablish Capacity of Process & Plant
5 Completed ISIR's on HEL Template
Demonstate Material meets Drawing
Specification
Demonstate Parts meet Drawing
Specification (if applicable)
Demonstate Parts meet Drawing
Specification (if applicable)
Demonstate Parts meet Drawing
Specification (if applicable)
Must include all process steps
(measurement, material storage, etc.)
To include action plan to reduce high
RPN's
Must include dimensional control,
attribute checks, SPC (were applicable)
and ongoing product validation I.e X-ray,
paint compliance etc.

8 Operator Process Instructions Work Instructions

9 Measurement System Analysis (MSA) How have you validated the gauges?
10 Packing Specification Packaging Media, Size, Quantities
11 Part Submission Warrant

Upon completion of the first production run

12 Process Capability Study Cpk Target Cpk value 1.67, to include action
plan / Gauge plan for non capable
specifications

WIF4521A Hendrickson PPAP Master Page 1

 APQP/PPAP
WORKBOOK V1.0
Copyright © 1998 March Quality Services

Part Name
Part Number
Engineering Change Level
Engineering Change Level Date

Supplier Name
Supplier Code
Street Address
City
State
Zip
Phone Number

Application

File Name
 Production Hendrickson
Tooling Report No
Title on Hendrickson Supplier Report
Drawing No
Drawing Number as shown on Prepared by
Hendrickson Drawing

Supplier Name Drg Sht No of pages

No Drg Issue
in report
Dimensional Report/ISIR
Feature Dimension Tolerance SC Supplier Results Out of Hendrickson Results
Ref Min Max limit

Date of
Supplier Approval
Approval
Hendrickson Quality Team Notes/Actions Weight (Kg)

Sample No

Supplier Comments

SCQE

Date
Sample Accepted /
Rejected IF IN DOUBT ASK
W.I.F.4506 Issue E 20 June 2007
 INITIAL SAMPLE INSPECTION REPORT - CONTINUATION SHEET
Drg Title Hendrickson Report Number
Drg Number
Supplier Name Supplier Report Number
No of pages in the report

Feature Supplier Result

Dimension Tolerance SC Out of Limit Hendrickson Result
Ref Min Max
Letter on the ISIR form Instruction for the completion of this area
If the samples been manufactured using production intent tooling,
A enter YES and 'NO' if not.

B This box is for Hendrickson Europe use ONLY.

C This is for SUPPLIER use to add unique number IF SO REQUIRED

D Enter the title of the part or assembly as shown on the drawing

E Enter the Drawing Number as stated on the drawing.

F Enter the name of the person who is compiling the ISIR report.
Enter the SUPPLIER name who has submitted the samples and
G documentation.

H Enter the Drawing Sheet Number as shown on the drawing.

I Enter the page number and the total number of pages in the report.

J Enter the Drawing Issue Number as shown on the drawing

K Enter a unique number for each dimension/note/feature

L Enter each dimension/note/feature as shown on the drawing

M Enter for each dimension the Tolerance as shown on the drawing

Enter a YES for each significant characteristic
N dimension/note/feature as shown on the drawing
Enter the results for all the dimensions specified in column L.
O smallest dimension in MIN column and the largest in the MAX
column
Enter the error for out of tolerance dimensions. Leave blank if the
P results are within drawing specification.

Q This column is for Hendrickson Europe use only.

R Name of the person who carried out or approves the assessment.

S Date of completion of the ISIR.

T This is for Hendrickson Europe use only.

U The actual weight of the component in Kilogrammes.

V Enter the number of the sample as identified on the part.

W This is for Hendrickson Europe use only.

X This is for Hendrickson Europe use only.

Completed by Hendrickson Europe Quality either Accept or Reject
Y the ISIR

Z Enter in here any comments the Supplier considers appropriate

 Production Hendrickson
Tooling A Report No B
Title on Hendrickson Supplier Report
Drawing D No C
Drawing Number as shown on Prepared by
Hendrickson Drawing E F
Supplier Name Drg Sht No of pages
No H I Drg Issue J
in report
G Dimensional Report/ISIR
Feature Dimension Tolerance SC Supplier Results Out of Hendrickson Results
Ref Min Max limit

.
K
O
L M
P

N Q

Date of
Supplier approval R S
Approval
Hendrickson Quality Team Notes/Actions Weight (Kg) U

Sample No V
T
Supplier Comments

SCQE W
Z
Date X
Sample Accepted /
Rejected Y IF IN DOUBT ASK
W.I.F.4506 Issue E 20 June 2007
 INITIAL SAMPLE INSPECTION REPORT - CONTINUATION SHEET
Drg Title D Hendrickson Report Number
Drg Number E B
Supplier Name Supplier Report Number
G
No of pages in the report I C
Feature Supplier Result
Dimension Tolerance SC Out of Limit Hendrickson Result
Ref Min Max

M
O
K
L
P

Q
 PROCESS FLOW DIAGRAM
PART NUMBER: 0 DATE:
PART DESCRIPTION: ECL: 0
0 PREPARED BY:
PROCESS

INSPECT
PRODUCT AND

ITEM #

ITEM #
STORE
MOVE

OPERATION PROCESS CONTROL

STEP DESCRIPTION CHARACTERISTICS METHODS

Page 9 of 17
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # 0 Rev. 0 (PROCESS FMEA) FMEA Number: 0
Item: 0 Process Responsibility: 0 Prepared by:
Model Year(s)/Vehicle(s) 0 Key Date Date (Orig.)
Team: Date (Rev.)
C Potential O D
Process Potential Potential S l Cause(s)/ c Current e R. Recommended Responsibility Action Results
Function/ Failure Effect(s) of e a Mechanism(s) c Process t P. Actions & Target Actions S O D R.
Require- Mode Failure v s of Failure u Controls e N. Date Taken e c e P.
ments s r c v c t N.

Page 10 of 17
 CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
0 0
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
0 0
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
0
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
0 0
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

Page 11 of 17
 Page 17 of 13 Pages

Production Part Approval -

Material Test Results

SUPPLIER PART NUMBER

0 0
NAME OF LABORATORY PART NAME
0
TYPE OF NOT
TEST MATERIAL SPEC. NO./DATE/SPECIFICATION SUPPLIER TEST RESULTS OK OK

SIGNATURE TITLE DATE

Operations Quality Manager

May 1995 CFG-1004

 Part Submission Warrant
Part Name 0 Part Number 0
Safety and/or Engineering Drawing
Government Yes No Change Level 0 Dated 0

Additional Engineering Changes Dated

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

Checking Aid Number Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

0 0 Dimensional Materials/Function Appearance

Supplier Name

0 Customer Name/Division 0 0
Street Address
Buyer/Buyer Code
0 0 00000
City State Zip Application 0

REASON FOR SUBMISSION

Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location

Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant, Appearance Approval Report (for designated appearance items only).

Level 2 - Warrant, Parts, Drawings, Inspection Results, Laboratory and Functional Results

Level 3 - At Customer Location - Warrant, Parts, Drawings, Inspection Results, Laboratory and Functional Results,
Appearance Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gage Study, FMEA.

Level 4 - Per level 3, but without parts.

Level 5 - At Supplier Location - Warrant, Parts, Drawings, Inspection Results, Laboratory and Functional Results,
Appearance Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gage Study, FMEA.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requirements: YES NO (If "NO" - Explanation Required)

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer
drawings and specifications and are made from specified materials on regular production tooling with no operations other than the
regular production process. I have noted any deviations from this declaration below.

EXPLANATION/COMMENTS:

Print Name Title Phone No. 0

Supplier Authorized Signature Date

FOR CUSTOMER USE ONLY

Part Disposition Approved Rejected Other

Customer Name Customer Signature Date

May 1995 CFG-1001

 GAGE REPEATABILITY AND REPRODUCIBILITY REPORT
SHORT FORM ATTRIBUTE RESULTS
Part Number Gage Name Appraiser A
0
Part Name Gage Number Appraiser B
0
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

All measurement decisions agree? Yes Accept Gage

No Reject Gage

Remarks
 GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A Part Number Gage Name Appraiser A
0 0
Part Name Gage Number Appraiser B Part Name Gage Number Appraiser B
0 0
Characteristic/Specification Gage Type Appraiser C Characteristic/Specification Gage Type Appraiser C

Characteristic Classification Trials Parts Appraisers Date Performed Characteristic Classification Trials Parts Appraisers Date Performed
0 0 0 0 0 0

APPRAISER/ PART AVERAGE Measurement Unit Analysis % Total Variation (TV)

TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)
1. A 1 EV = R x K1 Trials K1 % EV = 100 (EV/TV)

2. 2 = 2 4.56 =
3. 3 = 3 3.05 =
4. AVE Xa= Reproducibility - Appraiser Variation (AV)
5. R Ra= AV = {(XDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/TV)

6. B 1 = =
7. 2 = Appraisers 2 3 =
8. 3 K2 3.65 2.70 n = number of parts
9. AVE Xb= Repeatability & Reproducibility (R & R) r = number of trials
10. R Rb= R&R = {(EV2 + AV 2)}1/2 Parts K3

11. C 1 = 2 3.65 % R&R = 100 (R&R/TV)

12. 2 = 3 2.70 =
13. 3 Part Variation (PV) 4 2.30 =
14. AVE Xc = PV = RP x K3 5 2.08
15. R Rc= = 6 1.93 % PV = 100 (PV/TV)

16. PART X= = 7 1.82 =

AVE ( Xp ) Rp= Total Variation (TV) 8 1.74 =

17. (Ra + Rb + Rc) / (# OF APPRAISERS) = R= TV = {(R&R2 + PV 2)}1/2 9 1.67

18. (Max X - Min X) = XDIFF= = 10 1.62
19. R x D4* = UCLR= =
20. R x D3* = LCLR= All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).

* D4 =3.27 for 2 trials and 2.58 for 3 trials; D 3 = 0 for up to 7 trials. UCL R 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:
K1 is 5.15/d 2, where d 2 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/d 2, where d 2 is dependent on the number of operators (m) and (g) is 1, since there is only one range calculation.
K2 is 5.15/d 2, where d 2 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.