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Our Name: Adams Thermal Systems Customer Name: Behr Part Name: Part Number: Rev. Level: Rev. Date: Product Program: Key Production Date: LAST UPDATE
PPAP Customer Name: Behr Part Name: Part Number: Rev. Level: Product Program: PSO Submission Date:
PPAP
Customer Name: Behr
Product Program:
Part Name: Part Number:
Rev. Level:
0
Daimler Chrysler
Part Submission Warrant
Part Name
0
Safety and/or Government Regulation
Yes
0
Part Number
✘ No
Engineering Drawing Change Level
0
Additional Engineering Changes
Dated Dated
Shown on Drawing No.
0
Purchase Order No.
Checking Aid No.
Weight (kg)
Engineering Change Level
SUPPLIER MANUFACTURING INFORMATION
Dated
12/30/99
SUBMISSION INFORMATION
Adams Thermal Systems
✘
Dimensional
✘
Materials/Functional
Appearance
Supplier Code
Supplier Name & Supplier Code
Customer Name/Division
Behr
Buyer/Buyer Code
Street Address
MI
Application
State
City
Note:
12/30/99
0
Zip
Does this part contain any restricted or reportable substances.
Yes
✘
No
Are plastic parts identified with appropriate ISO marking codes
Yes
✘
No
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
Tooling Inactive > than 1 year
Other - please specify
REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report ) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. ✘
Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS The results for
✘ dimensional measurements
✘
These results meet all drawing and specification requirements:
material and functional tests ✘ Yes
appearance criteria
No
✘
statistical process package
(if "No" - Explanation Required)
Mold / Cavity / Production Process DECLARATION I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were produced at the production rate of
/ 8 hours. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS: Print Name:
Phone No:
Title:
Supplier Authorized Signature
Fax No. Date
FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition:
Approved
Rejected
Part Functional Approval:
Other Customer Name July 1999
CFG-1001
Approved Waived
Customer Signature The original copy of this document shall remain at the suppliers location while the part is active (see Glossary).
Date Optional: customer tracking number: # _______________
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 1 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 2 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 3 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 4 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Material Test Results Page 1 of 1 Pages
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF LABORATORY
0 PART NAME
0 TYPE OF
NOT
TEST
MAY 1995
MATERIAL SPEC. NO. / DATE / SPECIFICATION
CFG-1004
SUPPLIER TEST RESULTS
SIGNATURE
TITLE
QUALITY MGR.
OK
OK
DATE
PROCESS FLOW DIAGRAM PART NUMBER: 0
MFG. ENG.:
PART NAME: 0
QUAL. ENG.:
CUSTOMER: Behr
PLANT MGR.:
E.C.L.: 0
10
Inspect
n Store
Move
Operation
Step
tl
n
20
50
60
70
l
100
Key Product / Process Characteristics
Incoming Inspection
Load on Uncioler Straighten Oil Form
n
Inspect
t
Pack
l
110
120
Tool / Gage / Fixture / Location / Operator
Move To Press
t t t t
80
90
Operation Description
Store Material
30
40
REV. DATE: 11/18/04
Move to Shipping Store in Shipping
l
Ship
OPERATOR KEY TD
TRUCK DRIVER
MO
MACHINE / PRESS OPERATOR
MH
MATERIAL HANDLER / HI-LO
AO
ASSEMBLY OPERATOR
ST
STOCK / STORAGE
RC
RECEIVING CLERK
PT
PROCESS / PRESS TECHNICIAN
QA
QUALITY INSPECTOR
Flow10/26/2009
Page 11 of 23
FAILURE MODES EFFECT ANALYSIS
/
PART NAME AND NUMBER:
PROCESS RESPONSIBILITY:
FMEA DATE (ORIG.):
Rev Level/Date
KEY PRODUCTION DATE:
FMEA DATE (REV.):
CORE TEAM MEMBERS:
MODEL YEAR(S) / VEHICLE(S):
PREPARED BY:
PART NAME: S T E P
40
MODEL VEHICLE: Potential Failure Mode
Incoming Inspection Load Coil on Uncoiler Straighten
60
Oil
70
90
Form
Pack
D E T E C T
R P N
Check at receiving
1
4
Check Material Certification Check at Press
1
8
1
4
1
10
80
2
2
8
Visual inspection
8
80
4
Die problems
1
12
4
Visual inspection
8
96
2
Visual inspection
8
96
2
Part Layout
2
24
Die shut Ht. set incorrectly Die/Worn Broken
2
Part Layout
2
24
2 Die PM System
Part Layout/
2
24
Incorrect label installed Incorrect Date samped on Container
3
8
192
3
8
192
Potential Cause(s)/ Mechanism(s) of Failure
O C C U R
S E V
Incorrect material Dimensional
Non Conforming Product
4
Wrong Material Shipped to ATS
1
Incorrect alloy
Braze Problems at Behr Non Conforming Product
8
Wrong Material Shipped to ATS Wrong Material Shipped to ATS
1
Material Clad on Wrong Side Not Set Correctly
2
6
Oiler not working/ empty Oiler not working/ empty Oiler not working/ empty Oiler set too high
6
Incorrect Progression
6
Incorrect material Dimensional Clad on Wrong Side
50
C L A S S
Potential Effect(s) of Failure
Process Function
10
1/4/2005
Braze Problems at Behr Material not Straight Die Feed Problems into die Crakcing/ Thinning of Leaks on Assembly material Parts stick in die Non conforming Product- Dimensional Burrs on part Non conforming Product- Dimensional Oily Parts Braze Problems at Behr Progression set Incorrect Part Width/ incorrectly Collar Ht. Die Shut Ht. Incorrect Incorrect Collar Ht and Part Flatness Die Worn/Broken Non conforming Product- Dimensional No Build at Behr Wrong Part # on Container Wrong "Born on Date" Braze Problems at Behr
KB Stamping
4 8 2 5 3 3
6 8 8
Current Process Controls
Prevention
1
Detection
FMEA 11/1/04
Action Results Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
S E V
O C C
D E T
R P N
Page 12 of 23
FAILURE MODES EFFECT ANALYSIS PART NAME: S T E P
10
MODEL VEHICLE: Potential Failure Mode
Process Function
Incoming Inspection
Incorrect material Dimensional
KB Stamping
Potential Effect(s) of Failure
S E V
Non Conforming Product
4
C L A S S
Potential Cause(s)/ Mechanism(s) of Failure
Wrong Material Shipped to ATS
O C C U R 1
Current Process Controls
Prevention
Detection Check at receiving
FMEA 11/1/04
D E T E C T
R P N
1
4
Action Results Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
S E V
O C C
D E T
R P N
Page 13 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 SUPPLIER LOCATION:
FIRST ISSUED:
SUPPLIER PHONE:
REVISED:
PROCESS CONTROL PLAN
SUPPLIER CODE:
PART NUMBER/E.C.L.: / PART NAME: 0
SUPERCEDES:
PROTOTYPE
KB STAMPINGS REP. PLANT MGR.: _____________________ DATE: _____________
CUSTOMER REP. (IF APPLICABLE) Q.A. REP.: ___________________________
DATE: _____________
PRE-LAUNCH
MFG. ENG.: _______________________
DATE: _____________
ENG. REP.: __________________________
DATE: _____________
PRODUCTION
Q.A. MGR.: _______________________
DATE: _____________
MGMT. REP.: _________________________
DATE: _____________
Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
Rec Insp
KB Stamping
Production Control Plan 11/1/04
Page 14 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
10
20
30
KB Stamping
Production Control Plan 11/1/04
Page 15 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
KB Stamping
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Production Control Plan 11/1/04
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
Page 16 of 23
Production Inspection Sheet Check 1st piece at set-up or start of day and record data. Check 1 part at the start of each coil & 1 part per bin Check Last piece from Production Run, Record Data, Attach last & 1st piece part to fixture Shut down and notify Management of any non conformance Print Rev.: Rev Date: Customer: 0 12/30/99 Part Number: Part Name Lot No.: 0 0 Print Specification & Characteristic
KB Stamping
Sample No. 1
Sample No. 2
Sample No. 3
Production Inspection Sheet 01/27/03
Behr Date:
Sample No. 4
Sample No. 5
Page 17 of 23
OPERATION INSTRUCTIONS PART NAME:
0
PART NUMBER:
0
KB JOB NUMBER:
0
OPERATION(S):
WORK STATION
10 Progressive Complete
ISSUED BY:
DATE:
APPROVED BY:
DATE:
OPERATION METHOD
PACKAGING INSTRUCTIONS
OPERATOR 1) VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE. OP. 10 PRESS DIE
2) WHEN LOADING MATERIAL INTO DIE, ASSURE THAT IT IS ALIGNED "PARALLEL" TO THE DIE.
CONVEYOR TO CARDBOARD BOX
3) WHEN THE MATERIAL IS COMPLETELY LOADED, PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT. BOX
4) WHEN FIRST PIECE IS APPROVED, RUN PRESS IN FULL AUTOMATIC MODE.
FIRST PIECE AND IN PROCESS INSPECTION
5) MONITOR SCRAP REMOVAL SO THAT IT DOESN'T AFFECT DIE. GAGE TABLE
Place packaging picture here
6) WHEN THE CONTAINER IS FULLACCORDING TO PACKAGING INSTRUCTIONS.
FINISH GOODS SKID
7) APPLY COMPLETED PRODUCT INVENTORY LABEL TO SKID.
QUALITY CRITERIA
GAGE INSTRUCTIONS 7) USE FEELER GAGES TO VERIFY PROPER FORM / FORM LOCATION AS SHOWN ON FIXTURE.
Place part picture here
5. 1) PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 2) PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.
8) USE YELLOW SCRIBE LINES TO VERIFY PROPER TRIM LOCATIONS.
7.
3) PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 4) CLAMP PART ONTO FIXTURE 5)
INSERT 11.80MM STAB PIN INTO CENTER HOLE TO VERIFY POSITION
8.
6.
6) REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10 STAB PIN INTO EACH SLOT TO VERIFY POSITION FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS. RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.
DIE SETUP SHEET
SUBJECT PRESS SIZE STOCK (MATERIAL) SIZE COUNTER BALANCE PRESSURE SHUT HEIGHT FEED ROLLER PRESSURE MATERIAL FEED DISTANCE MATERIAL FEED RATE STRAIGHTENING PRESSURE PILOT RELEASE PRESSURE STROKES PER MINUTE OIL (LUBRICANT) AIR HOOK-UP SENSOR HOOK-UP
KB JOB NUMBER:
0
ISSUED BY:
DATE:
PART NAME:
0
APPROVED BY:
DATE:
CUSTOMER:
Behr
REQUIREMENT
Place picture of die in press here….
DIE PROTECTION SHORT FEED PART EJECT
ON
OFF
CAM SWITCH FEED ADVANCE PILOT RELEASE
ON
OFF
TONNAGE REFERENCE DIE LOCATION TONNAGE LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR TOTAL TONNAGE
TYPE
SHAKER REFERENCE SIZE LOCATION
COMMENTS 1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK. 2. 3. 4. 5. 6.
Item ID 1 2 Micrometer 3 Tape Measure 4 5 6 7 8 9 10
Item Description 0-1" Mic - Material Thickness Verification Tape - Material Width Verification
SPECIAL CHARACTERISTICS LIST PART NAME:
No. 1 2 3 4
Description/Rationale
Form Revision: 11/3/04
PART NUMBER:
Specification/Tolerance Class. -
Illustration/Pictorial
Page 21 of 23
Predictive Maintenance Check List 0
Die Number:
Date:
Guidance
250,000
300,000
350,000
400,000
450,000
500,000
Weight Nitro Pressure Danger
200,000
Information Tags
150,000
Punch/Bull Ring Mounting Wear Plates Storage Cushions Balance Blocks
100,000
Cycle Frequency
50,000
Indicate cycle
x
x
x
x
x
x
x
x
x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x Check for Legibility x Check for Legibility x Check for Legibility
Guide Pins Guide Bushings
Prox. Switches Cords Boxes Surface Wear
x x x x x
x x x
x x x x x
x x x
Cavity/Pad Punch Post Plate type Pin type Punch Rubbing
x x x x x
x x x
x x x x x
x x x
x Check for leaks x Check for leaks x x x
x x x x x x
x x x
x x x
x x x
x x x
Gauging
x x x
x x x
x x x
x x x
x Check for damage x Check for damage x Check for damage x Check Nitro Log and/or replace x Replace
Wear Plates Pins & Bushings Rail Gauge Solid Gauge Bottom Blocks
x Check x Check x Check x Check for surface damage x One or x the other
Nitro Air Internal Pad
Check/tighten screws Return to original sizes Check and/or replace Check and/or replace
x Check for wear, replace x Check for wear, replace
x
Lifters Cylinders
Do all activities marked with an "x"
x Return to original sizes x Replace bushings/check pins
x x x
x x
x x
x x
x x x
x x
x x
x x
x x
x Check for tight/position/damage x Check for tight/position/damage x Check for tight/position/damage
"X"= Done. 0 = no action needed. NA = not in this die. Legend for complete column
Comments:
Actual Time Spent
Checklist Completed By:
C o m p l e t e
PREVENTIVE MAINTENANCE WORK INSTRUCTION Control Object: Reason: Responsibility:
Use of this instruction will enable the Die Preventive Maintenance Areas to warrant the tools that have been PM'd as fit for service when returned to their production line. This instruction serves as a reminder to the die maker to check critical areas on the tools and repair/replace those areas that may be a problem during a production run. The die maker will perform this maintenance before returning the tools to production and inform the supervisor of any problem that requires scheduled release time to correct.
Instructions: 1) Check punch and resurface as needed 2) Check upper and lower Steels for wear. Repair as needed. 3) Check beads and gutters for wear. Repair as needed. 4) Check nitro cylinders for leaks. Replace as needed 5) Check lifter system for damage. Repair as needed 6) Check heel and wear plates for proper clearance and wear. Tighten/replace as needed. 7) Check risers and punch mounting plates for loose and missing screws. Tighten/replace as needed. 8) Clean disassembled die. Lubricate where necessary. 9) Check and re-size / re-shim equalizer blocks. 10) Check bolster plate mounting screws. Tighten/replace as needed.
Approval:
Date:
Concurrence:
Date:
Date Revised:
Date Issued:
PPAP Customer Name: Behr Part Name: Part Number: Rev. Level: Product Program: PSO Submission Date:
PPAP
Customer Name: Behr
Product Program:
Part Name: Part Number:
Rev. Level:
0
Daimler Chrysler
Part Submission Warrant
Part Name
0
Safety and/or Government Regulation
Yes
0
Part Number
✘ No
Engineering Drawing Change Level
0
Additional Engineering Changes
Dated Dated
Shown on Drawing No.
0
Purchase Order No.
Checking Aid No.
Weight (kg)
Engineering Change Level
SUPPLIER MANUFACTURING INFORMATION
Dated
12/30/99
SUBMISSION INFORMATION
Adams Thermal Systems
✘
Dimensional
✘
Materials/Functional
Appearance
Supplier Code
Supplier Name & Supplier Code
Customer Name/Division
Behr
Buyer/Buyer Code
Street Address
MI
Application
State
City
Note:
12/30/99
0
Zip
Does this part contain any restricted or reportable substances.
Yes
✘
No
Are plastic parts identified with appropriate ISO marking codes
Yes
✘
No
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
Tooling Inactive > than 1 year
Other - please specify
REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report ) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. ✘
Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS The results for
✘ dimensional measurements
✘
These results meet all drawing and specification requirements:
material and functional tests ✘ Yes
appearance criteria
No
✘
statistical process package
(if "No" - Explanation Required)
Mold / Cavity / Production Process DECLARATION I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were produced at the production rate of
/ 8 hours. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS: Print Name:
Phone No:
Title:
Supplier Authorized Signature
Fax No. Date
FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition:
Approved
Rejected
Part Functional Approval:
Other Customer Name July 1999
CFG-1001
Approved Waived
Customer Signature The original copy of this document shall remain at the suppliers location while the part is active (see Glossary).
Date Optional: customer tracking number: # _______________
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 1 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 2 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 3 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Dimensional Results Page 4 of 4
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF INSPECTION FACILITY
0 PART NAME
0 NOT ITEM
DIMENSION / SPECIFICATION
SUPPLIER TEST RESULTS
OK
OK
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 MAY 1995
CFG-1003
SIGNATURE
TITLE
DATE
GM
Daimler Chrysler
Production Part Approval ___ Material Test Results Page 1 of 1 Pages
SUPPLIER
PART NUMBER
Adams Thermal Systems NAME OF LABORATORY
0 PART NAME
0 TYPE OF
NOT
TEST
MAY 1995
MATERIAL SPEC. NO. / DATE / SPECIFICATION
CFG-1004
SUPPLIER TEST RESULTS
SIGNATURE
TITLE
QUALITY MGR.
OK
OK
DATE
PROCESS FLOW DIAGRAM PART NUMBER: 0
MFG. ENG.:
PART NAME: 0
QUAL. ENG.:
CUSTOMER: Behr
PLANT MGR.:
E.C.L.: 0
10
Inspect
n Store
Move
Operation
Step
tl
n
20
50
60
70
l
100
Key Product / Process Characteristics
Incoming Inspection
Load on Uncioler Straighten Oil Form
n
Inspect
t
Pack
l
110
120
Tool / Gage / Fixture / Location / Operator
Move To Press
t t t t
80
90
Operation Description
Store Material
30
40
REV. DATE: 11/18/04
Move to Shipping Store in Shipping
l
Ship
OPERATOR KEY TD
TRUCK DRIVER
MO
MACHINE / PRESS OPERATOR
MH
MATERIAL HANDLER / HI-LO
AO
ASSEMBLY OPERATOR
ST
STOCK / STORAGE
RC
RECEIVING CLERK
PT
PROCESS / PRESS TECHNICIAN
QA
QUALITY INSPECTOR
Flow10/26/2009
Page 11 of 23
FAILURE MODES EFFECT ANALYSIS
/
PART NAME AND NUMBER:
PROCESS RESPONSIBILITY:
FMEA DATE (ORIG.):
Rev Level/Date
KEY PRODUCTION DATE:
FMEA DATE (REV.):
CORE TEAM MEMBERS:
MODEL YEAR(S) / VEHICLE(S):
PREPARED BY:
PART NAME: S T E P
40
MODEL VEHICLE: Potential Failure Mode
Incoming Inspection Load Coil on Uncoiler Straighten
60
Oil
70
90
Form
Pack
D E T E C T
R P N
Check at receiving
1
4
Check Material Certification Check at Press
1
8
1
4
1
10
80
2
2
8
Visual inspection
8
80
4
Die problems
1
12
4
Visual inspection
8
96
2
Visual inspection
8
96
2
Part Layout
2
24
Die shut Ht. set incorrectly Die/Worn Broken
2
Part Layout
2
24
2 Die PM System
Part Layout/
2
24
Incorrect label installed Incorrect Date samped on Container
3
8
192
3
8
192
Potential Cause(s)/ Mechanism(s) of Failure
O C C U R
S E V
Incorrect material Dimensional
Non Conforming Product
4
Wrong Material Shipped to ATS
1
Incorrect alloy
Braze Problems at Behr Non Conforming Product
8
Wrong Material Shipped to ATS Wrong Material Shipped to ATS
1
Material Clad on Wrong Side Not Set Correctly
2
6
Oiler not working/ empty Oiler not working/ empty Oiler not working/ empty Oiler set too high
6
Incorrect Progression
6
Incorrect material Dimensional Clad on Wrong Side
50
C L A S S
Potential Effect(s) of Failure
Process Function
10
1/4/2005
Braze Problems at Behr Material not Straight Die Feed Problems into die Crakcing/ Thinning of Leaks on Assembly material Parts stick in die Non conforming Product- Dimensional Burrs on part Non conforming Product- Dimensional Oily Parts Braze Problems at Behr Progression set Incorrect Part Width/ incorrectly Collar Ht. Die Shut Ht. Incorrect Incorrect Collar Ht and Part Flatness Die Worn/Broken Non conforming Product- Dimensional No Build at Behr Wrong Part # on Container Wrong "Born on Date" Braze Problems at Behr
KB Stamping
4 8 2 5 3 3
6 8 8
Current Process Controls
Prevention
1
Detection
FMEA 11/1/04
Action Results Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
S E V
O C C
D E T
R P N
Page 12 of 23
FAILURE MODES EFFECT ANALYSIS PART NAME: S T E P
10
MODEL VEHICLE: Potential Failure Mode
Process Function
Incoming Inspection
Incorrect material Dimensional
KB Stamping
Potential Effect(s) of Failure
S E V
Non Conforming Product
4
C L A S S
Potential Cause(s)/ Mechanism(s) of Failure
Wrong Material Shipped to ATS
O C C U R 1
Current Process Controls
Prevention
Detection Check at receiving
FMEA 11/1/04
D E T E C T
R P N
1
4
Action Results Recommended Action(s)
Responsibility & Target Completion Date
Actions Taken
S E V
O C C
D E T
R P N
Page 13 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 SUPPLIER LOCATION:
FIRST ISSUED:
SUPPLIER PHONE:
REVISED:
PROCESS CONTROL PLAN
SUPPLIER CODE:
PART NUMBER/E.C.L.: / PART NAME: 0
SUPERCEDES:
PROTOTYPE
KB STAMPINGS REP. PLANT MGR.: _____________________ DATE: _____________
CUSTOMER REP. (IF APPLICABLE) Q.A. REP.: ___________________________
DATE: _____________
PRE-LAUNCH
MFG. ENG.: _______________________
DATE: _____________
ENG. REP.: __________________________
DATE: _____________
PRODUCTION
Q.A. MGR.: _______________________
DATE: _____________
MGMT. REP.: _________________________
DATE: _____________
Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
Rec Insp
KB Stamping
Production Control Plan 11/1/04
Page 14 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
10
20
30
KB Stamping
Production Control Plan 11/1/04
Page 15 of 23
KB Stamping 8110 Graphic Dr.-Belmont, MI. 49306 Phone:(616) 866-5917 Fax: (616) 866-5918 Part Name
Model Vehicle Process Name/ Operation Description
Part/ Process Number
KB Stamping
Machine, Device, Jig, Dies For Mfg.
KB NUMBER:
Characteristics
No.
Product
Methods
Process
Special Char. Class
Product/Process Specification/ Tolerance
Evaluation Measurement Technique
Production Control Plan 11/1/04
Sample
Reaction Plan
ACTUAL MEASUREMENT
Control Method Size
Freq.
Page 16 of 23
Production Inspection Sheet Check 1st piece at set-up or start of day and record data. Check 1 part at the start of each coil & 1 part per bin Check Last piece from Production Run, Record Data, Attach last & 1st piece part to fixture Shut down and notify Management of any non conformance Print Rev.: Rev Date: Customer: 0 12/30/99 Part Number: Part Name Lot No.: 0 0 Print Specification & Characteristic
KB Stamping
Sample No. 1
Sample No. 2
Sample No. 3
Production Inspection Sheet 01/27/03
Behr Date:
Sample No. 4
Sample No. 5
Page 17 of 23
OPERATION INSTRUCTIONS PART NAME:
0
PART NUMBER:
0
KB JOB NUMBER:
0
OPERATION(S):
WORK STATION
10 Progressive Complete
ISSUED BY:
DATE:
APPROVED BY:
DATE:
OPERATION METHOD
PACKAGING INSTRUCTIONS
OPERATOR 1) VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE. OP. 10 PRESS DIE
2) WHEN LOADING MATERIAL INTO DIE, ASSURE THAT IT IS ALIGNED "PARALLEL" TO THE DIE.
CONVEYOR TO CARDBOARD BOX
3) WHEN THE MATERIAL IS COMPLETELY LOADED, PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT. BOX
4) WHEN FIRST PIECE IS APPROVED, RUN PRESS IN FULL AUTOMATIC MODE.
FIRST PIECE AND IN PROCESS INSPECTION
5) MONITOR SCRAP REMOVAL SO THAT IT DOESN'T AFFECT DIE. GAGE TABLE
Place packaging picture here
6) WHEN THE CONTAINER IS FULLACCORDING TO PACKAGING INSTRUCTIONS.
FINISH GOODS SKID
7) APPLY COMPLETED PRODUCT INVENTORY LABEL TO SKID.
QUALITY CRITERIA
GAGE INSTRUCTIONS 7) USE FEELER GAGES TO VERIFY PROPER FORM / FORM LOCATION AS SHOWN ON FIXTURE.
Place part picture here
5. 1) PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 2) PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.
8) USE YELLOW SCRIBE LINES TO VERIFY PROPER TRIM LOCATIONS.
7.
3) PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO VERIFY CORRECT SIZE. 4) CLAMP PART ONTO FIXTURE 5)
INSERT 11.80MM STAB PIN INTO CENTER HOLE TO VERIFY POSITION
8.
6.
6) REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10 STAB PIN INTO EACH SLOT TO VERIFY POSITION FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS. RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.
DIE SETUP SHEET
SUBJECT PRESS SIZE STOCK (MATERIAL) SIZE COUNTER BALANCE PRESSURE SHUT HEIGHT FEED ROLLER PRESSURE MATERIAL FEED DISTANCE MATERIAL FEED RATE STRAIGHTENING PRESSURE PILOT RELEASE PRESSURE STROKES PER MINUTE OIL (LUBRICANT) AIR HOOK-UP SENSOR HOOK-UP
KB JOB NUMBER:
0
ISSUED BY:
DATE:
PART NAME:
0
APPROVED BY:
DATE:
CUSTOMER:
Behr
REQUIREMENT
Place picture of die in press here….
DIE PROTECTION SHORT FEED PART EJECT
ON
OFF
CAM SWITCH FEED ADVANCE PILOT RELEASE
ON
OFF
TONNAGE REFERENCE DIE LOCATION TONNAGE LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR TOTAL TONNAGE
TYPE
SHAKER REFERENCE SIZE LOCATION
COMMENTS 1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK. 2. 3. 4. 5. 6.
Item ID 1 2 Micrometer 3 Tape Measure 4 5 6 7 8 9 10
Item Description 0-1" Mic - Material Thickness Verification Tape - Material Width Verification
SPECIAL CHARACTERISTICS LIST PART NAME:
No. 1 2 3 4
Description/Rationale
Form Revision: 11/3/04
PART NUMBER:
Specification/Tolerance Class. -
Illustration/Pictorial
Page 21 of 23
Predictive Maintenance Check List 0
Die Number:
Date:
Guidance
250,000
300,000
350,000
400,000
450,000
500,000
Weight Nitro Pressure Danger
200,000
Information Tags
150,000
Punch/Bull Ring Mounting Wear Plates Storage Cushions Balance Blocks
100,000
Cycle Frequency
50,000
Indicate cycle
x
x
x
x
x
x
x
x
x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x Check for Legibility x Check for Legibility x Check for Legibility
Guide Pins Guide Bushings
Prox. Switches Cords Boxes Surface Wear
x x x x x
x x x
x x x x x
x x x
Cavity/Pad Punch Post Plate type Pin type Punch Rubbing
x x x x x
x x x
x x x x x
x x x
x Check for leaks x Check for leaks x x x
x x x x x x
x x x
x x x
x x x
x x x
Gauging
x x x
x x x
x x x
x x x
x Check for damage x Check for damage x Check for damage x Check Nitro Log and/or replace x Replace
Wear Plates Pins & Bushings Rail Gauge Solid Gauge Bottom Blocks
x Check x Check x Check x Check for surface damage x One or x the other
Nitro Air Internal Pad
Check/tighten screws Return to original sizes Check and/or replace Check and/or replace
x Check for wear, replace x Check for wear, replace
x
Lifters Cylinders
Do all activities marked with an "x"
x Return to original sizes x Replace bushings/check pins
x x x
x x
x x
x x
x x x
x x
x x
x x
x x
x Check for tight/position/damage x Check for tight/position/damage x Check for tight/position/damage
"X"= Done. 0 = no action needed. NA = not in this die. Legend for complete column
Comments:
Actual Time Spent
Checklist Completed By:
C o m p l e t e
PREVENTIVE MAINTENANCE WORK INSTRUCTION Control Object: Reason: Responsibility:
Use of this instruction will enable the Die Preventive Maintenance Areas to warrant the tools that have been PM'd as fit for service when returned to their production line. This instruction serves as a reminder to the die maker to check critical areas on the tools and repair/replace those areas that may be a problem during a production run. The die maker will perform this maintenance before returning the tools to production and inform the supervisor of any problem that requires scheduled release time to correct.
Instructions: 1) Check punch and resurface as needed 2) Check upper and lower Steels for wear. Repair as needed. 3) Check beads and gutters for wear. Repair as needed. 4) Check nitro cylinders for leaks. Replace as needed 5) Check lifter system for damage. Repair as needed 6) Check heel and wear plates for proper clearance and wear. Tighten/replace as needed. 7) Check risers and punch mounting plates for loose and missing screws. Tighten/replace as needed. 8) Clean disassembled die. Lubricate where necessary. 9) Check and re-size / re-shim equalizer blocks. 10) Check bolster plate mounting screws. Tighten/replace as needed.
Approval:
Date:
Concurrence:
Date:
Date Revised:
Date Issued:
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