ppap templates
DESCRIPTION
PPAP Templates, Excel file PPAPProduction part approval processTRANSCRIPT
PPAP Submission
Date Initiated:
Part Name
Part Number
Purchase Order #
Engineering Change Level
Engineering Change Level Date
Supplier Name
Street Address
City
State
Zip
Phone Number
Supplier Contact
PPAP Submission Level GuideQuick reference
Level 4 - Will be defined by ACTIA during the PPAP request
Level 4a - Predetermined by ACTIA
Level 4b - Predetermined by ACTIA
The additional comments below are only an ACTIA summary of AIAG manual.Refer to AIAG Manual current edition for complete information.
Lev
el 1
Lev
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Lev
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Lev
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Lev
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a
Lev
el 4
b
Lev
el 5 Additional Comments
1 X X X * X X X ACTIA PSW only
2 X X * X X X
3 X X * X X X
4 X * X X
5 Design FMEA, X * X
6 X * X X
7 Process FMEA X * X
8 Control Plan X * X X
Ele
me
nt
Ord
er
PPAP RequirementsAIAG PPAP Fourth Edition
Required Documents
Part Submission Warrant (PSW)
Upon completion of all PPAP requirements, the organization shall complete the Part submission warrant (PSW).
If production parts will be produced from more than one cavity, mold, tool die, pattern, or Production process e.g., line or cell, the organization shall complete
a dimensional evaluation on one part from each . These specifics cavities, molds, line, etc..., shall then be identified in the "Mold/Cavity/Production
Process" line on a PSW, or in a PSW attachment. A responsible official of the organization shall approve the PSW and provide contact information.
Design Records & Bubbled part print(s).
ACTIA design record bubbled
The organization shall have the design record for the saleable product/part, including design records for components or details of the saleable product / part. Where the design record is in electronic format, e.g., CAD/CAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric
dimensioning & tolerancing (GD&T) sheets, drawing) to identify measurements taken.
Authorized Engineering Change
Documentation
Various engineering documentation
The organization shall have any authorized engineering change documents form those changes not yet recorded in the design record but incorporated in
the product, part or tooling.
Customer Engineering Approvals
Customer engineering approval proof
Where specified by the customer, the organization shall have evidence of customer engineering approval.
Can be ACTIA DFMEA Format or an AIAG compliant DFMEA.
The product design-responsible organization shall develop a Design FMEA in accordance with and compliant to, customer specified requirements.(e.g.,
potential Failure Mode and Effects Analysis reference manual)
Process Flow Diagrams
Any standard flowchartformat.
The organization shall have a process flow diagram in an organization-specified format that clearly describes the production process steps and
sequence, as appropriate, and meets the specified customer needs, requirements and expectations (e.g., Advanced Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a process
Flow Diagram is a Process Flow Description.
Can be ACTIA PFMEA Format or an AIAG compliant PFMEA.
The organization shall develop a process FMEA in accordance with and compliant to, customer-specified requirements, (e.g., Potential Failure Mode
and Effects Analysis reference manual)
Can be ACTIA format or AIAG compliant format.
The organization shall have a control plan that defines all methods used for process control and complies with customer-specified requirements (e.g., Advanced Product Quality Planning and Control Plan reference manual).
9 X * X Not required by ACTIA
10 Dimensional Results X X * X X X
11-1 X X * X X X
11-2 X X * X X X
12 X * X
13 X X * X X X
Measurement System Analysis
Studies
The organization shall have applicable Measurement System analysis studies, e.g., gage R&R, bias, linearity, stability, for all new or modified gages,
measurement, and test equipment.( see the Measurement Systems Analysis reference manual)
Can use ACTIA Format or an AIAG compliantformat
for dimention report
The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and result
indicate compliance with specified requirements. The organization shall have dimensional results for each unique manufacturing process, e.g., cells or production lines and all cavities, molds, patterns or dies. The organization
shall record , with the actual results : all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record
and Control Plan. The organization shall identify the parts measured.
Material Test Results and Performance test
result and related design notes
Industry Standard reports or test result formats
designated by ACTIA.
Material test results shall indicate and include :1) The design record change level of the parts tested;
2) Any authorized engineering change documents that not yet been incorporated in the design record;
3) The number, date, and change level of the specification to which the part was tested;
4) the date on which the testing took place;5) the quantity tested; 6) the actual results;
7) The material supplier's name and, when required by the customer, the customer-assigned supplier/vendor code.
Performance Test Results
Industry Standard reports or test result formats
designated by ACTIA .
The organization shall perform tests for all part(s) or product material(s) when performance or functional requirements are specified by the design record or
Control Plan. Performance test results shall indicate and include : 1) The design record change level of the parts tested;
2) Any authorized engineering change documents that not yet been incorporated in the design record;
3) The number, date, and change level of the specification to which the part was tested;
4) the date on which the testing took place;5) the quantity tested; 6) the actual results;
Initial Process Study (Cpk) Capability
Studies
Process Capability Study using any statistical package or ACTIA Capability Form.
The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by
the customer or organization. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to
submission.- Where no special characteristics have been identified, the customer reserve
the right to require demonstration of initial process capability on other characteristics.
Index > 1.67 : the process currently meets the acceptance criteria.1.33=< Index =< 1.67 : the process may be acceptable. Contact the authorized
customer representative for review of the study results.Index <1.33 : Process does not currently meet the acceptance criteria. Contact
the authorized customer representative for a review of study results.
Qualified Laboratory Documentation
Lab Scope and outside labproof of accreditation.
Inspection and testing for PPAP shall be performed by qualified laboratory as defined by customer requirements (e.g. an accredited laboratory). the qualified
laboratory (internal or external to the organization) shall have a laboratory scope and documentation showing that the laboratory is qualified for the type
of measurements or tests conducted.When an external/Commercial laboratory is used, the organization shall
submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s)
of the tests, and the standards used to run the tests shall be identified.
14 X X X * X X X
15 X X * X X X Upon ACTIA requirements The organization shall provide sample product as specified by the customer.
16 Master Samples * X X X Uppon Actia requirements
17 Checking aids * X X X
18 * X X
Appearance ApprovalReport
ACTIA format or AIAG format
A separate Appearance Approval Report (AAR) shall be completed for each part or series of part if the product/part has appearance requirements on the
design record.Upon satisfactory completion of all required criteria, the organization shall
record the required information on the AAR. The completed AAR and representative production product/part shall be submitted to the location
specified by the customer to receive disposition. AARs (complete with part disposition and authorized customer representative signature) shall then
accompany the PSW at the time of final submission based upon the submission level requested.
Sample Product Parts
The organization shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced
for the same customer part number for customer approval, or b) where a master sample is required by the design record, Control Plan or inspection
criteria, as a reference or standard. The master sample shall be identified as such, and shall show the customer approval date on the sample. The
organization shall retain a master sample for each position of a multiple cavity die, mold tool or pattern, or production process unless otherwise specified by
the customer. When part size , sheet volume of parts, etc. makes storage of a master
sample difficult, the sample retention requirements may be modified or waived in writing by authorized customer representative.
Part specific assembly or checking aids
If requested by customer, the organization shall submit with the PPAP submission any pert specific assembly or component checking aid.
Customer specific requirements
To submit for PCA suppliers only
The organization shall have records of compliance to all applicable customer-specific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirement
Checklist.
PPAP SAMPLE PARTS - LABEL
PPAP SAMPLE PARTSINSPECTION VERIFICATION REQUIRED
Purchase Order#: 0
Part Number: 0
Revision Level: 0
Supplier Name: 0
Send identified sample(s). Each sample used for PPAP must be clearly identified with their identification number corresponding with data.
Please complete, print in color and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label.
In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.
Page 6 of 28
Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)
Process Responsibility FMEA Date
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item
Nu
mb
er
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
Potential Failure Modes and Effects AnalysisDesign FMEA
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
Page 7 of 28
Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)
Process Responsibility FMEA Date
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item
Nu
mb
er
Requirements
Current Product Controls Action Results
Prevention Detection Actions Taken
Potential Failure Modes and Effects AnalysisDesign FMEA
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
0 0
Process flowPart # 0 Control plan NumberPart Name 0 Prepared ByRev # 0 Control plan Date (Orig.)
Control plan Date
Operation Transport Inspect Store Idle
10
20
30
40
50
60
Process ResponsibilityProcess
No.
Page 9 of 28
Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)Process Responsibility FMEA Date
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Pro
cess
Nu
mb
er
Requirements
Current Process 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
Potential Failure Modes and Effects AnalysisProcess FMEA
Process/StepFunction
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
Page 10 of 28
Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)Process Responsibility FMEA Date
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Pro
cess
Nu
mb
er
Requirements
Current Process Controls Action Results
Prevention Detection Actions Taken
Potential Failure Modes and Effects AnalysisProcess FMEA
Process/StepFunction
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
0 0
Page 11 of 28
Control Plan
Control Plan Number Key Contact / Phone Date (Orig.) Current Release Level Current Release Date
Part Number Latest Change (Rev) Level Part Description Plant Location0 0 0
Core Team Supplier Name Quality Department Approval
0
CHARACTERISTICSMETHODS
CONTROL METHOD REACTION PLAN
SAMPLE
NO. PRODUCT PROCESS SIZ
E
FR
EQ
PA
RT
/
PR
OC
ES
S
NU
MB
ER PROCESS
NAME / OPERATION
DESCRIPTION
MACHINE DEVICES / JIG / TOOLS FOR
MANUFACTURINGSPECIAL
CHAR. CLASS
PRODUCT / PROCESS /
SPECIFICATION / TOLERANCE
EVALUATION/MEASUREMENT
TECHNIQUE
Prototype Pre-Launch Production
DIMENSIONAL RESULT
Part name 0 Tooling num
Part number: 0 Cavity #
Revision # 0 Sample size :
Cavity number: Check by:
Total # of measurements taken = 0Total # of measurements within in spec = 0
% of measurements meeting spec = #DIV/0!
Bu
bb
le #
SpecificationActual measurements
Re
su
lt
Sample 1 Sample 2 Sample 3
Gauge Type
Low.tol.
Upp.tol.
Insp Pts
# out of tol
Bu
bb
le #
SpecificationActual measurements
Re
su
lt
Sample 1 Sample 2 Sample 3
Gauge Type
Low.tol.
Upp.tol.
Insp Pts
# out of tol
Bu
bb
le #
SpecificationActual measurements
Re
su
lt
Sample 1 Sample 2 Sample 3
Gauge Type
Low.tol.
Upp.tol.
Insp Pts
# out of tol
comment
comment
comment
Part Submission WarrantPart Name 0 Part Number 0Safety and/orGovernment Regulation Yes No Engineering Drawing Change Level 0 Dated
Additional Engineering Changes Dated
Shown on Drawing no. Purchase order No. 0 Weight (kg)
Checking Aid No. Engineering Change Level Dated
ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION0 Customer Name / Division
Supplier Name Buyer Name/Code0 Application
Street Address0 0 0
City State Zip
Note: Does this part contain any restricted or reportable substances Yes No N/A
Are plastic parts identified with appropriate ISO marking codes Yes No N/A
REASON FOR SUBMISSION
Initial Submission Change to Optional Construction or MaterialEngineering Change(s) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or additional Change in Part processingCorrection of Discrepancy Parts Produced at Additional LocationTooling Inactive > than 1 year Other - please specify
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant, only (and for designated 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. Include Level (4a) and (4b) predefined in ACTIA procedure.
(Check)Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)Mold / Cavity / Production Process:
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicableProduction Part Approval Process Manual 4th Edition Requirements. I further warrant these samples wereproduced at the production rate of / 8 hours. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS:
Print Name Title Phone No. FAX No.
Supplier Authorized Signature Date
Part Warrant Disposition:Rejection/Other Comments:
Customer Name Customer Signature Date
FOR ACTIA USE ONLY (IF APPLICABLE)
APPROVED REJECTED OTHER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Production Part Approval Material Test Results and Related Design Record Notes
PART NUMBER: 0 DESIGN RECORD CHANGE LEVEL: 0
PART NAME: 0 ENGINEERING CHANGE DOCUMENTS date: 12/30/1899
NAME of LABORATORY:
MATERIAL SPEC. NO. / REV / DATESUPPLIER TEST RESULTS (DATA) OK
Blanket statements of conformance are unacceptable for any test results.
SIGNATURE TITLE DATE
Bubble #
SPECIFICATION / LIMITS
TEST DATE
QTY. TESTED
NOT OK
Production Part Approval Performance Test Results and Related Design Record Notes
PART NUMBER: 0 DESIGN RECORD CHANGE LEVEL: 0
PART NAME: 0 ENGINEERING CHANGE DOCUMENTS DATE: 12/30/1899
TEST SPECIFICATION / REV / DATE SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS OK
SIGNATURE TITLE DATE
Bubble #
SPECIFICATION / LIMITS
TEST DATE
QTY. TESTED
NOT OK
INITIAL SAMPLES CAPABILITY REPORT
Part Name : 0Part number : 0 Revision #
Drawing number : 0Tool number :
Cavity number :Check by :
Inspection date :
Gauge type
0 030 10
N° Data Cp Cpk Average
1
234
Maxi. Mini Range56 0.00 0.00 0.000 0 789
101112131415161718192021222324252627282930
Comments :
Nominal.dim.
Low.tol.
Upp.tol.
Low.dim.
Upp.dim.
Samplesize
Cat. nbr.
OkOut
Std.deviation
Out of spec.
#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!#D
IV/0
!0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0%
200%
400%
600%
800%
1000%
1200%
0
Histogram
Inch
QT
Y
Comments :
ACTIA Corporation APPEARANCE APPROVAL REPORT
Part Name 0 Part number 0
Revision level 0 0
Supplier name 0
PPAP ELEMENTSA
PP
LIC
AB
LE
AC
CE
PT
ED
COMMENTS
1 COLOR N/A
2 BRILLANCE N/A
3 GLOSS N/A
4 GRAIN N/A
5 TRANSPARENCY N/A
6 SINK MARK N/A
7 WELDING LINES N/A
8 INJECTION GATE N/A
9 KNIT LINE MARK N/A
10 EJECTOR MARKS N/A
11 PAINT N/A
12 MARKING AND DECORATION (Silk-screen printing, Pad printing) N/A
14 Approved Sample Matched N/A
ECN change level date
Supplier 0 Part name 0
Part # 0 Revision level 0
ACTIA Special requirement Bill Of Material review (Applicable for PCA only)
Bubble Number on
BOM
Is component present?
Is component orientation correct?
Bubble Number on
BOM
Is component present?
Is component orientation correct?
Form 4.7.19 Revision C 6-23-10
Document Number:
SUPPLIER DEVIATION REQUEST ACTIA SUPPLIER TO COMPLETE
Supplier Name: Part Number: Part Name:
0 0 0
Date: P.O.# P.O Qty Qty Produced Scheduled Delivery Date Contact Name:
EMAIL:
Type of deviation:
Quantity: PO's affected:
From: To: PO's affected:
How does this deviation affect the scheduled delivery date of the product?
Date approval needed to meet scheduled delivery date?
Submit this deviation request to ACTIA Purchasing
ACTIA PURCHASING TO COMPLETE
Date product needed to meet order dates?
Quantity needed to meet order dates?
ACTIA ENGINEERING AND QUALITY TO COMPLETE
Approved by: Name: Date:Engineering:
Quality:
By: Date:
ACTIA customer approval/PPAP submission required.
Submitted: **Add reason below:
Approved by: Name: Date:** Please provide the customer approval for this deviation. Engineering:
Quality:
ACTIA ENGINEERING TO COMPLETE
Reason:
By: Date:
Quantity: PO's affected:
From: To: PO's affected:
ECN #:
Comments:
Return this completed document to ACTIA Purchasing.
ACTIA PURCHASING FORWARD THIS COMPLETED DOCUMENT TO THE SUPPLIER
Reason: (Please include a physical sample or picture depicting the deviation to be approved.)
Add the document number and forward to ACTIA Engineering and Quality.
No ACTIA customer approval required - No customer specification or drawing requirements.
* This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers original responsibility for insuring that all characteristics, designated in the applicable engineering specifications
and/or inherent in the samples as originally tested and approved, are maintained.
Limited QtyLimited TimePermanent
APPROVED*
REJECTED
Limited QtyLimited TimePermanent
Yes No
PFMEA LISTS 4th Edition DFMEA LISTS 4th EditionSEVERITY SCALE SEVERITY SCALE 10 Noncompliance to a government regulation 10 Affects safe vehicle operation and/or noncompliance to a government regulation without warning. 9 A safety hazard 9 Affects safe vehicle operation and/or noncompliance to a government regulation with warning. 8 Will result in customer complaint and return of product 8 Loss of primary function (vehicle inoperable but does not affect safe vehicle operation. 7 May cause production disruption or failure of sales specification. 7 Degradation of Primary function (vehicle operable but at a reduced level of performance) 6 Will be caught at subsequent processing. 6 Loss of secondary function (vehicle operatable but comport/ convenience functions inoperable. 5 Will be caught during processing 5 Degradation of secondary function (vehicle operatable but comfort/ convenience functions inoperable. 4 Likely to be caught by customer at incoming inspection 4 Appearance of audible noise, vehicle operable, item does not conform, and noticed by most customers (75%). 3 Only a slight inconvenience with product or processing noticed 3 Appearance of audible noise, vehicle operable, item does not conform, and noticed by many customers (50%). 2 Likely to cause only a slight customer annoyance 2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%). 1 Not likely to cause any effect or to be noticed by customer 1 No discernible affect.OCCURRENCE SCALE OCCURRENCE SCALE10 High frequency, No Background 10 New technology/new design with no history. 9 High frequency, Assumption 9 Failure is inevitable with new design, new application, or change in duty cycle/operating conditions. 8 High frequency, Similar Experience 8 Failure is likely with new design, new application, or change in duty cycle/operating conditions. 7 High frequency, Actual Experience 7 Failure is uncertain with new design, new application, or change in duty cycle/operating conditions. 6 Moderate Frequency, Assumption 6 Frequent failures associated with similar designs or in design simulation and testing. 5 Moderate Frequency, Similar Experience 5 Occasional failures associated with similar designs or in design simulation and testing. 4 Moderate Frequency, Actual Experience 4 Isolated failures associated with similar designs or in design simulation and testing. 3 Low Frequency, Assumption 3 Only isolated failures associated with almost identical design or in design simulation or testing. 2 Low Frequency, Similar Experience 2 No observed failures associated with almost identical design or in design simulation or testing. 1 Low Frequency, Actual Experience 1 Failure is eliminated through preventative control.DETECTION SCALE DETECTION SCALE10 Absolute certainty of Non-detection. 10 No current design control; Cannot detect or is not analyzed. 9 Very low likelihood of detection. 8 Controls may detect at end of customer production. 7 Controls may detect existence during customer production. 6 Controls likely to detect defect in lot inspection but higher variability. 5 Controls likely to detect defect in lot inspection. 4 Controls have a good chance of detecting defect at end of current process step. 3 Controls have a good chance of detecting defect before end of current process step. 2 Controls almost certainly defect before next process. 1 Controls detect defect before next process. 1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)
9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is 8 Product verification after design freeze and prior to launch with 7 Product verification after design freeze and prior to launch with 6 Product verification after design freeze and prior to launch with 5 Product validation (reliability testing, development or validation tests) prior to design freeze using 4 Product validation (reliability testing, development or validation tests) prior to design freeze using 3 Product validation (reliability testing, development or validation tests) prior to design freeze using 2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is
DFMEA LISTS 4th EditionSEVERITY SCALE 10 Affects safe vehicle operation and/or noncompliance to a government regulation without warning. 9 Affects safe vehicle operation and/or noncompliance to a government regulation with warning. 8 Loss of primary function (vehicle inoperable but does not affect safe vehicle operation. 7 Degradation of Primary function (vehicle operable but at a reduced level of performance) 6 Loss of secondary function (vehicle operatable but comport/ convenience functions inoperable. 5 Degradation of secondary function (vehicle operatable but comfort/ convenience functions inoperable. 4 Appearance of audible noise, vehicle operable, item does not conform, and noticed by most customers (75%). 3 Appearance of audible noise, vehicle operable, item does not conform, and noticed by many customers (50%). 2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%). 1 No discernible affect. OCCURRENCE SCALE 10 New technology/new design with no history. 9 Failure is inevitable with new design, new application, or change in duty cycle/operating conditions. 8 Failure is likely with new design, new application, or change in duty cycle/operating conditions. 7 Failure is uncertain with new design, new application, or change in duty cycle/operating conditions. 6 Frequent failures associated with similar designs or in design simulation and testing. 5 Occasional failures associated with similar designs or in design simulation and testing. 4 Isolated failures associated with similar designs or in design simulation and testing. 3 Only isolated failures associated with almost identical design or in design simulation or testing. 2 No observed failures associated with almost identical design or in design simulation or testing. 1 Failure is eliminated through preventative control.DETECTION SCALE 10 No current design control; Cannot detect or is not analyzed.
1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)
9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is not correlated 8 Product verification after design freeze and prior to launch with pass/fail testing (Subsystem or system testing with acceptance criteria such as ride and handling , shipping evaluation etc.) 7 Product verification after design freeze and prior to launch with test to failure testing (Subsystem or system testing until failure occurs, testing of interactions etc.) 6 Product verification after design freeze and prior to launch with degradation testing (Subsystem or system testing after durability test e.g. functional test. 5 Product validation (reliability testing, development or validation tests) prior to design freeze using pass/fail testing (e.g.. acceptance criteria for performance functional checks etc.) 4 Product validation (reliability testing, development or validation tests) prior to design freeze using test to failure 3 Product validation (reliability testing, development or validation tests) prior to design freeze using degradation (e.g. data trends, before/after values etc.) 2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is highly correlated
2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%).
1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)
9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is not correlated to expected or actual operating conditions. Not likely to detect at any stagetesting (Subsystem or system testing with acceptance criteria such as ride and handling , shipping evaluation etc.)
testing (Subsystem or system testing until failure occurs, testing of interactions etc.) testing (Subsystem or system testing after durability test e.g. functional test.
pass/fail testing (e.g.. acceptance criteria for performance functional checks etc.) test to failure (e.g. until leaks, yields or cracks etc.)degradation (e.g. data trends, before/after values etc.)
2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is highly correlated with actual or expected operating conditions.