apqp forms
TRANSCRIPT
Our Name: Adams Thermal Systems
Customer Name: Behr
Part Name:Part Number:
Rev. Level:Rev. Date:
Product Program:
Key Production Date:
LAST UPDATE
PPAPCustomer Name: Behr
Part Name: Part Number: Rev. Level:
Product Program:
PSO Submission Date:
PP
AP
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Part Submission WarrantPart Name 0 Part Number 0
Safety and/orGovernment Regulation Yes No Engineering Drawing Change Level 0 Dated 0
Additional Engineering Changes Dated
Shown on Drawing No. 0 Purchase Order No. Weight (kg)
Checking Aid No. Engineering Change Level Dated 0
SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION
Adams Thermal Systems Dimensional Materials/Functional Appearance
Supplier Name & Supplier Code Supplier CodeCustomer Name/Division Behr
Street Address Buyer/Buyer Code
MI Application 0
City State Zip
Note: 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 material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requirements: (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: Title: Phone No: Fax No.
Supplier Authorized Signature Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Warrant Disposition: Approved Rejected Part Functional Approval: Approved
Other Waived
Customer Name Customer Signature Date
July The original copy of this document shall remain at the suppliers location Optional: customer tracking
1999 while the part is active (see Glossary). number: # _______________CFG-1001CFG-1001
NoYes
Daimler Chrysler
Production Part Approval ___Dimensional Results
Page 1 of 4
SUPPLIER PART NUMBER
Adams Thermal Systems 0NAME OF INSPECTION FACILITY PART NAME
0NOT
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 CFG-1003 SIGNATURE TITLE DATE
1995
GMDaimler Chrysler
Production Part Approval ___Dimensional Results
Page 2 of 4
SUPPLIER PART NUMBER
Adams Thermal Systems 0NAME OF INSPECTION FACILITY PART NAME
0NOT
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 CFG-1003 SIGNATURE TITLE DATE
1995
GMDaimler Chrysler
Production Part Approval ___Dimensional Results
Page 3 of 4
SUPPLIER PART NUMBER
Adams Thermal Systems 0NAME OF INSPECTION FACILITY PART NAME
0NOT
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 CFG-1003 SIGNATURE TITLE DATE
1995
GMDaimler Chrysler
Production Part Approval ___Dimensional Results
Page 4 of 4
SUPPLIER PART NUMBER
Adams Thermal Systems 0NAME OF INSPECTION FACILITY PART NAME
0NOT
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 CFG-1003 SIGNATURE TITLE DATE
1995
GMDaimler Chrysler
Production Part Approval ___Material Test Results
SUPPLIER PART NUMBER
Adams Thermal Systems 0NAME OF LABORATORY PART NAME
0TYPE OF NOT
TEST MATERIAL SPEC. NO. / DATE / SPECIFICATION SUPPLIER TEST RESULTS OK OK
MAY CFG-1004 SIGNATURE TITLE DATE
1995 QUALITY MGR.
Page 1 of 1 Pages
GMDaimler Chrysler
PROCESS FLOW DIAGRAM
Flow04/08/2023 Page 10 of 21
PART NUMBER: 0 MFG. ENG.:
PART NAME: 0 QUAL. ENG.:
CUSTOMER: Behr PLANT MGR.:
E.C.L.: 0
t l n
Ste
p
Ope
ratio
n
Mov
e
Sto
re
Ins
pect Operation Description
10 n Incoming Inspection
20
Store Material
30 l Move To Press
40 t Load on Uncioler
50 t Straighten
60 t Oil
70 t Form
80
n Inspect
90 t Pack
100 l Move to Shipping
110
Store in Shipping
120 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
REV. DATE: 11/18/04
Tool / Gage / Fixture / Location / Operator Key Product / Process Characteristics
FAILURE MODES EFFECT ANALYSIS
KB Stamping FMEA 11/1/04 Page 11 of 21
PART NAME AND NUMBER: / PROCESS RESPONSIBILITY: FMEA DATE (ORIG.): 1/4/2005
Rev Level/Date KEY PRODUCTION DATE: FMEA DATE (REV.):
CORE TEAM MEMBERS: MODEL YEAR(S) / VEHICLE(S): PREPARED BY:
PART NAME: MODEL VEHICLE:
Current Process Controls Action Results
Prevention Detection
10 4 1 Check at receiving 1 4
Incorrect alloy 8 1 1 8
40 4 1 Check at Press 1 4
Clad on Wrong Side 8 1 10 80
50 Straighten Die Feed Problems 2 Not Set Correctly 2 2 8
60 Oil Leaks on Assembly 5 2 Visual inspection 8 80
Parts stick in die 3 4 Die problems 1 12
Burrs on part 3 4 Visual inspection 8 96
Oily Parts 6 Oiler set too high 2 Visual inspection 8 96
70 Form 6 Incorrect Progression 2 Part Layout 2 24
Die Shut Ht. Incorrect 6 2 Part Layout 2 24
Die Worn/Broken 6 Die/Worn Broken 2 Die PM System Part Layout/ 2 24
90 Pack No Build at Behr 8 3 8 192
8 3 8 192
STEP
ProcessFunction
PotentialFailureMode
PotentialEffect(s) of
Failure
SEV
CLASS
PotentialCause(s)/
Mechanism(s)of Failure
OCCUR
DETECT
RPN
RecommendedAction(s)
Responsibility& Target
Completion DateActionsTaken
SEV
OCC
DET
RPN
Incoming Inspection
Incorrect material - Dimensional
Non Conforming Product
Wrong Material Shipped to ATS
Braze Problems at Behr
Wrong Material Shipped to ATS
Check Material Certification
Load Coil on Uncoiler
Incorrect material - Dimensional
Non Conforming Product
Wrong Material Shipped to ATS
Braze Problems at Behr
Material Clad on Wrong Side
Material not Straight into dieCrakcing/ Thinning of material
Oiler not working/ empty
Non conforming Product- Dimensional
Oiler not working/ empty
Non conforming Product- Dimensional
Oiler not working/ empty
Braze Problems at Behr
Progression set incorrectly
Incorrect Part Width/ Collar Ht.Incorrect Collar Ht and Part Flatness
Die shut Ht. set incorrectly
Non conforming Product- Dimensional
Wrong Part # on Container
Incorrect label installed
Wrong "Born on Date"
Braze Problems at Behr
Incorrect Date samped on Container
KB Stamping8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
KB Stamping Production Control Plan 11/1/04 Page 12 of 21
KB STAMPINGS REP. CUSTOMER REP. (IF APPLICABLE)
PART NUMBER/E.C.L.: PLANT MGR.: _____________________ DATE: _____________ Q.A. REP.: ___________________________ DATE: _____________
/
MFG. ENG.: _______________________ DATE: _____________ ENG. REP.: __________________________ DATE: _____________
PART NAME:
0 Q.A. MGR.: _______________________ DATE: _____________ MGMT. REP.: _________________________ DATE: _____________
Part Name Model Vehicle KB NUMBER: Characteristics Methods
Reaction Plan ACTUAL MEASUREMENTNo. Product Process
SampleControl Method
Size Freq.
Rec
Insp
SUPPLIER LOCATION: FIRST ISSUED:
SUPPLIER PHONE: REVISED:
SUPPLIER CODE: SUPERCEDES:
PROTOTYPE
PRE-LAUNCH
PRODUCTION
Part/ProcessNumber
Process Name/
OperationDescription
Machine, Device,Jig, DiesFor Mfg.
SpecialChar.Class
Product/ProcessSpecification/
Tolerance
EvaluationMeasurement
Technique
PROCESS CONTROL PLAN
KB Stamping8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
KB Stamping Production Control Plan 11/1/04 Page 13 of 21
Part Name Model Vehicle KB NUMBER: Characteristics Methods
Reaction Plan ACTUAL MEASUREMENTNo. Product Process
SampleControl Method
Size Freq.
Part/ProcessNumber
Process Name/
OperationDescription
Machine, Device,Jig, DiesFor Mfg.
SpecialChar.Class
Product/ProcessSpecification/
Tolerance
EvaluationMeasurement
Technique
10
20
30
KB Stamping8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
KB Stamping Production Control Plan 11/1/04 Page 14 of 21
Part Name Model Vehicle KB NUMBER: Characteristics Methods
Reaction Plan ACTUAL MEASUREMENTNo. Product Process
SampleControl Method
Size Freq.
Part/ProcessNumber
Process Name/
OperationDescription
Machine, Device,Jig, DiesFor Mfg.
SpecialChar.Class
Product/ProcessSpecification/
Tolerance
EvaluationMeasurement
Technique
Production Inspection Sheet
KB Stamping Production Inspection Sheet 01/27/03 Page 15 of 21
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 conformancePrint Rev.: Rev Date: Customer:
0 0 BehrPart Number: Part Name Lot No.: Date:
0 0
Sample No. 1 Sample No. 2 Sample No. 3 Sample No. 4 Sample No. 5Print Specification & Characteristic
OPERATION INSTRUCTIONS
Form Revision: 10/04/04 Page 16 of 21
PART NAME: 0 OPERATION(S): 10 Progressive Complete ISSUED BY: DATE:
PART NUMBER: 0 APPROVED BY: DATE:
KB JOB NUMBER: 0
WORK STATION OPERATION METHOD PACKAGING INSTRUCTIONS
OPERATOR
1)
2)
3)
4)
5) Place packaging picture here
6)
7)
QUALITY CRITERIA GAGE INSTRUCTIONS
7) USE FEELER GAGES
TO VERIFY PROPER
FORM / FORM
LOCATION AS SHOWN
ON FIXTURE.
Place part picture here
1)8) USE YELLOW
SCRIBE LINES TO2) VERIFY PROPER TRIM
LOCATIONS.
3)
4) CLAMP PART ONTO FIXTURE
5)
6)
FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS.
RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.
VERIFY MATERIAL THICKNESS PRIOR TO LOADING MATERIAL INTO DIE.
WHEN LOADING MATERIAL INTO DIE, ASSURE THAT IT IS ALIGNED "PARALLEL" TO THE DIE.
WHEN THE MATERIAL IS COMPLETELY LOADED, PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT.
WHEN FIRST PIECE IS APPROVED, RUN PRESS IN FULL AUTOMATIC MODE.
MONITOR SCRAP REMOVAL SO THAT IT DOESN'T AFFECT DIE.
WHEN THE CONTAINER IS FULLACCORDING TO PACKAGING INSTRUCTIONS.
APPLY COMPLETED PRODUCT INVENTORY LABEL TO SKID.
PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.
PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.
PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO VERIFY CORRECT SIZE.
INSERT 11.80MM STAB PIN INTO CENTER HOLE TO VERIFY POSITION
REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10 STAB PIN INTO EACH SLOT TO VERIFY POSITION
OP. 10PRESS
DIE
FINISH GOODS SKID
GAGETABLE
FIRST PIECE AND IN
PROCESS INSPECTION
CONVEYOR TO CARDBOARD BOX
5.
6.
7.
8.
BOX
DIE SETUP SHEET
Form Revision: 10/26/04 Page 17 of 21
KB JOB NUMBER: 0 ISSUED BY: DATE:
PART NAME: 0 APPROVED BY: DATE:
CUSTOMER: Behr
SUBJECT REQUIREMENT
PRESS SIZE STOCK (MATERIAL) SIZECOUNTER BALANCE PRESSURESHUT HEIGHTFEED ROLLER PRESSUREMATERIAL FEED DISTANCEMATERIAL FEED RATESTRAIGHTENING PRESSUREPILOT RELEASE PRESSURESTROKES PER MINUTEOIL (LUBRICANT)AIR HOOK-UP Place picture of die in press here….SENSOR HOOK-UP
DIE PROTECTION ON OFFSHORT FEEDPART EJECT
CAM SWITCH ON OFFFEED ADVANCEPILOT RELEASE
TONNAGE REFERENCEDIE LOCATION TONNAGE
LEFT FRONTLEFT REARRIGHT FRONTRIGHT REAR
TOTAL TONNAGE
SHAKER REFERENCETYPE SIZE LOCATION COMMENTS
1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK.2.3.4.5.6.
Item ID Item Description
12 Micrometer 0-1" Mic - Material Thickness Verification3 Tape Measure Tape - Material Width Verification456789
10
Form Revision: 11/3/04 Page 19 of 21
SPECIAL CHARACTERISTICS LIST
PART NAME: PART NUMBER:
No. Description/Rationale Specification/Tolerance Class. Illustration/Pictorial1 -2 -3 -4 -
-
Predictive Maintenance Check ListDie Number: 0 Date:Indicate cycle
Cycle Frequency 50
,00
0
10
0,0
00
15
0,0
00
20
0,0
00
25
0,0
00
30
0,0
00
35
0,0
00
40
0,0
00
45
0,0
00
50
0,0
00
Punch/Bull Ring Mounting x x x x x x x x x x Check/tighten screwsWear Plates x Return to original sizes
Storage Cushions x x x x x x x x x x Check and/or replaceBalance Blocks x x x x x x x x x x Check and/or replace
Information Weight x x x x x x x x x x Check for LegibilityTags Nitro Pressure x x x x x x x x x x Check for Legibility
Danger x x x x x x x x x x Check for Legibility
Guidance Guide Pins x Check for wear, replace Guide Bushings x x Check for wear, replace
Lifters x x x x x Check for leaksCylinders x x x x x Check for leaks
Prox. Switches x x x x x x x x x x Check Cords x x x x x x x x x x Check Boxes x x x x x x x x x x Check
Surface Wear Cavity/Pad x x Check for surface damagePunch x x One or
Post x x the other
Plate type x x x x x x x x x x Check for damagePin type x x x x x x x x x x Check for damage
Punch Rubbing x x x x x x x x x x Check for damage
Nitro x Check Nitro Log and/or replaceAir x Replace
Internal Wear Plates x Return to original sizesPad Pins & Bushings x x Replace bushings/check pins
Gauging Rail Gauge x x x x x x x x x x Check for tight/position/damageSolid Gauge x x x x x x x x x x Check for tight/position/damage
Bottom Blocks x x Check for tight/position/damage
Comments:
Actual Time Spent
Checklist Completed By:
Complete
Do all activities marked with an "x"
"X"= Done. 0 = no action needed. NA = not in this die.Legend for complete column
PREVENTIVE MAINTENANCE WORK INSTRUCTIONControl Object: 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.Reason: 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.Responsibility: 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: