AS Process Flow Diagram

Process xxxxxx
Inspection Key

Scrap/ Contain

Changeover

Movement
Operation

Store/Get

Rework
Process

Inspect
Move
Sequence Process Step Equipment Used
Number

A
A
 Product: Changeover Key
iagram Drawing Number: P = Product D = Dunnage
Prepared By:
xx Supplier:
T = Tooling
S = Software
L = Label

Equipment Used No of Operators Approx Time

Changeover Key Inspection Key Date Prepared: (DD/MM/YY) 12 January 2012
D = Dunnage A = Automatic Q = Quality Audit Effective Date: (DD/MM/YY) 12 January 2012
L = Label M = Manual Revision
V = Visual 1

SOP Reference Remarks

2012
2012
 Product:
AS CTQ Agreement Matrix Drawing Number:
Prepared By:
Product: xxxxxx Supplier:

Type of Measurement
Product Measurement
Set Up CTQ In Process Visual
oduct: Date Prepared: (DD/MM/YY)
awing Number: Effective Date: (DD/MM/YY)
epared By: Revision
pplier: 1

rement Drawing
Status Process Identification Approval
Visual Type
-

-
-

-
-

-
-

-
-

-
-

-
-

-
-

-
-

-
 AS Inspection Control Plan
Product: xxxxxx
Measurement Desc
Measurement Inspection Location/Machine
Measurement Description
Reference (English) Language If
 Product: Date Prepared: (DD/MM/YY)
ol Plan Drawing Number: Effective Date: (DD/MM/YY)
Prepared By: Revision
x Supplier: 1

Measurement Description Drawing Dimension

(Local Drawing Number (Reference size only - not controlled)
Language If Applicable) Size Upper Tol Lower Tol Set Up
 Severity Risk Score Key Severity Score Occurrence Risk Score Key Number Produce
Severity = How much of an Low 1 Occurrence = The number 1-Feb
Revision issue would it be for the Med 5 of occasions during shift 2-Oct
1 customer to have a High 10 the measurement >10

Risk Scores
Type of Measurement
Severity Occurrence Quantity Detection
Set Up CTQ In Process Visual Type
Number Produced Score Quantity Risk Score Key Number Produced Score Quantity Risk Score Key
1-Feb Low 1 Quantity = Number of <100/hr Low 1
Quantity = Number of pieces th
2-Oct Medium 5 pieces the machine could 100-400 Medium 5 machine could produce in an hou
>10 High 10 produce in an hour. >400/ hr High 10

Measurement Method -
Inspection Frequency Calibration Procedure Number
Risk Score Gauge Type

- -

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- -

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uantity Risk Score Key Number Produced Score Number Produced Score
Measurement will pass GRR <20% Low 1 Visual High 10
ty = Number of pieces the Measurement will pass GRR 30-40% Medium 5
e could produce in an hour.
Measurement will pass GRR >40% High 10
Gauge RR Results Capability
Reaction Plan Reference
GRR Short Term Long Term Number
Complete % Tol % Process
Cp Cpk Pp Ppk
n Plan Reference
Number
 FMEA Date (Orig.) : (DD/MM/YY)
FMEA Number : (DD/MM/YY)
FMEA Rev No:
FMEA Dates FMEA date (Revision) : (DD/MM/YY)

Supplier

Process Step/ Function Potential Failure Mode Potential Effects of Failure Causes of Fai
 AS Process FMEA
Product/Process: xxxxxx
Class
-
C Critical
FMEA Key I Important
F Functional
U Unimportant

Current process Severity Score

Current Controls, Prevention

Causes of Failure Class
and/or detection Causes of Potential
I Failure
EA
xxxxx
Severity Scoring Key Occurrence Detection Scoring Key
G P R
Critical 9-10 Severe - Very Severe 9-10 >=1000 pieces per 1000 9-10 Sample inspection AQL (9) - No Inspection (1
mportant 7-8 High - Very High 7-8 High - frequent Failure 7-8 Random Sample (8) - 100% Using Go No-Go
nctional 5-6 Low - Moderate 5-6 Moderate - Occasional Failures 5-6 Some SPC (7) - 100% Manual Inspection (6)
mportant 2-4 Very Minor to Very Low 2-4 Low - few Failures 2-4 SPC (4) -100% Automatic Inspection(2)
1 None 1 Failure Unlikely 1 Defect obvious or 100% Automatic inspectio

Total Score 0
Recommended Improvements
of Potential Current process Controls Current process Controls
P R IPR
ailure Prevention Detection

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
 Product: Date Prepared: (DD/MM/YY)
Drawing Number: Effective Date: (DD/MM/YY)
Prepared By: Revision
Supplier: 1
Detection Scoring Key
Core Team
R
ction AQL (9) - No Inspection (10) Team Members Name
ple (8) - 100% Using Go No-Go Gauges (7)
- 100% Manual Inspection (6)
% Automatic Inspection(2)
us or 100% Automatic inspection(1)

Current process
mended Improvements Responsibility for Action Action Actually Taken Date Completed
New Score
G
red: (DD/MM/YY)
ate: (DD/MM/YY)
Revision
1

Job Function

Current process Severity Score

New Score 0
G P R IPR
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

0
 Product Submission Warrant
AWI Product Details
Product Name Cust. Product Number

Drawing Number Orig. Product Number

Engineering Change Level Dated

Safety and/or Government Regulation Purchase Order No. Weight (kg)

Yes No
Checking Aid Number Checking Aid Eng. Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION AWI SUBMITTAL INFORMATION

Organization Name & Supplier Code Customer Name/Division

Street Address Buyer/Buyer Code

City Region Postal Code Country Other Details

MATERIALS REPORTING
n
Has customer-required Substances of Concern information been reported?
Yes No /
Submitted by IMDS or other customer format: a

n
Are polymeric Products identified with appropriate ISO marking codes?
Yes No /
Are the Statutory and Homologation test passed be the Product ? n
a
Yes No /
a
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 Product Processing
Correction of Discrepancy Products produced at Additional Location
Tooling/Production 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 organization's manufacturing location.

SUBMISSION RESULTS
The results for dimensional material and appearance statistical process
These results meet allmeasurements
design record requirements: functional tests criteria
(If "NO" package
- Explanation Required)
Yes NO
Mold / Cavity / Production Process

DECLARATION
I affirm that the samples represented by this warrant are representative of our Products, which were made by a process that meets all
Production Product Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the
production rate of ____/____ hours. I also certify that documented evidence of such compliance is on file and available for your review.
I have noted any deviation from this declaration below.

EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered? n/

Yes No
a
Organization Authorized Signature Date

Print Name Phone No. Fax No.

Title E-mail

FOR AWI use Only :

PPAP Warrant Disposition: Othe

Approved Rejected r
SQE/Head Signature Date

Customer Name PSW Submission Number

FR/RE/SDQ/20 PSW - Royal Enfield

 AS Measuring Equipment Con

Product: xxxxxx

Process Number Process Step Measurement Used For Measuring

 Product:
Equipment Control Plan Drawing Number:

duct: xxxxxx Supplier:

Gauge Drawing Nu
d For Measuring Measuring Equipment Model Sample Photo Relevant
 Date Prepared: (DD/MM/YY)
Effective Date: (DD/MM/YY)
Revision
1

Gauge Drawing Number if Internet Link - Measuring Equipment Supplier

Relevant
 AS Powder and Pre Coat Colour A

Colour: xxxxxx

Colour Description RAL Code If Relevant Paint Supplier Paint Supplier RM Code
L - Max

L
 Product:
re Coat Colour Agreement Drawing Number:

lour: xxxxxx Supplier:

Armstrong Specification - Approved by Corporate Quality

L - Max L - Min A- Max A - Min B- Max B- Min dE- Max dE- Min Gloss Max

Supplier Readings
Thickness
L B A dE Gloss Thickness Hardness Adhesion Max

Armstrong Readings Using Local BYK Colour Spectrometer

Thickness
L B A dE Gloss Thickness Hardness Adhesion Max
 Date Prepared: (DD/MM/YY)
Effective Date: (DD/MM/YY)
Revision
1

ved by Corporate Quality

Thickness Thickness Hardness Hardness
Gloss Max Gloss Min Adhesion
Max Min Max Min

Master Sample Held By Supplier Date of Sample DD/MM/YY

Thickness
Max

Master Sample Held By Armstrong Date of Sample DD/MM/YY

Thickness
Max
***** Left Deliberately Blank *****
Type Of Measurement Type GRR

Set Up Variable - Physical Data Yes

CTQ Attribute - Visual No
In Process
Visual
 Drop Down Tables

Status Drawing Approval Score Class

OK - Measurement System Available Yes 1 Critical

OK - In Improvement No 2 Important
No inspection Method - Data - In 3 Fictional
Improvement
In Improvement - Go/Nogo 4 Unimportant
Drawing Update required 5
Measurement Not Needed 6
7
8
9
10
 Measurement
Mesh CTQs Version 2
Measurement #

CTQ

Producton

Measur
ement Visual
Product

Measuring tool
x
x
x
x
x
x

BL302
ok

Control at
Process No.
update
drawing
not needed

BL302 MEGA
ok - in improvement

Control at
Process No.
update
drawing
in improvement - go/nogo
no detection - in improvement

RL201
update drawing - ok - in improvement

Control at
OK

Process No.
drawing

RL201 MEGA

Control at
OK

Process No.
drawing
Process No.

FL601
I65 Cutting

E09 Molding
E20 Laser Cutting

Control at
OK
E18 Manual Cutting

Process No.
drawing

RH215
E37 Notching Man. e/o PXN

Control at
OK

Process No.
drawing

RH215 MEGA

Control at
OK
E24
E16
E40
E19
E13

Process No.
drawing

RH215 END
Folding

Painting
Roll forming

Control at
to be

Process No.
tested
Manual Welding
Assembing (Robot)

RH200

Control at
OK

Process No.
drawing

RH200 LONG

Control at
OK

Process No.
drawing

RH200 MEGA

Control at
OK

Process No.
drawing

FH600

Control at
OK

Process No.
drawing

DH700

Control at
Process No.
update comments

DH700 MEGA

Control at
Process No.
update comments

BH300

Control at
Process No.
OK drawing

xx

Control at
Process No.

xx

Control at
Process No.
OK drawing

xx

Control at
Process No.
OK drawing

xx

Control at
Process No.
OK drawing

xx

Control at
Process No.
OK drawing

xxx

Control at
Process No.
OK drawing

xxx

Control at
Process No.
update comments