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Check SheetLear Automotive India Pvt. Ltd.,NasikPPAP CHECK LISTPart No. : Rev. No. :Customer : Lear Automotive India Pvt. Ltd.Description : Supplier :Sample Labels Required :Submission Level :Sr.NoRequirementLevel 3Remarks1Design records of saleable productsS- For Prorietary Components / DetailsR- For All Other Components / DetailsS2Engineering Change Documents, if anyS3Customer Engineering Approval if requiredS4Design FMEA ( See I.2.2.4)S5Process Flow Diagram *S6Process FMEA *S7Dimensional ResultsS(Layout Inspection Results) 8Material, Performance test resultsS(For all the components) 9Initial process studyS10Measurement system analysis studySRefer the MSA Acceptance guidelines in MSA Manual Section D 11Qualified laboratory documentationS12Control plan *S13Part submission warrant (PSW) *S14Appreance approval report, (AAR) if ApplicableS15Bulk Material requirement checklist (For bulk material PPAP only)R16Sample ProductS17Master Sample (See I.2.2.17)R18Checking aidsR19Record Of Compliance With Customer Specific RequirementSNOTE : Check for supplier PPAP completion* - Need approval signature

YESNO14325

Timing ChartAPQP TIME PLANLear Automotive India Pvt. LtdSupplierDuroshox Technologies Pvt. Ltd.CustomerLear Automotive India Pvt. Ltd.LocationRanjangaon ,PuneProgramMNAL W935Supplier CodeModel Year2009Part No.L0206690AAPart NameASM, ADJUSTER - 4 WAY MANUAL, CENTER, HEIGHT ADJUSTMENT,BS DR,RHDBuildMaterial Required DateQty.No. Of SCNo. Of CC% PIST%PIPCVP Build20.10.0835PP Build25.03.0950SOP10.05.0950TaskProgramm Need DateSupplier Commitment DateCompletion DateResponsibiltyCommentsPlan & Define1Business Plan/Marketing Strategy30.08.082Product/Process Benchmark DataNA3Product/Process AssumptionsNA4Product Reliability StudiesNA5Customer Inputs01.09.086Design GoalsNA7Preliminary Bill of Materials01.09.088Preliminary Process Flow Chart10.10.089Preliminary Listing of Special Product & Process Characteristics05.10.0810Product Assurance Plan10.10.08Product Design & Development11Design Failure Mode & Effects Analysis (DFMEA)NA12Design for Manufacturability & AssemblyNA13Design VerificationNA14Design ReviewsOngoingTasks 1-15 are optional, unless supplier is design responsible15Prototype Build - Control Plan10.10.0816Engineering Drawings (including math data)25.12.08Final Release.Released for VP on 23.10.0817Engineering Specifications25.12.08Final Release.Released for VP on 23.10.0818Material Specifications25.12.08Final Release.Released for VP on 23.10.0819Drawing & Specifications28.12.08Final Release.Released for VP on 23.10.0820New Equipment, Tooling & Facilities Requirements03.01.09This for Final release.For VP: 23.09.0821Special Product / Process Requirements06.01.09This for Final release.For VP: 23.09.0822Gages/Testing Equipment Requirements06.01.09This for Final release.For VP: 23.09.0823Team Feasibility Commitment10.01.09This for Final release.For VP: 23.09.08Process Design & Development24Packaging Standards15.01.0925Process Quality System ReviewOngoing26Process Flow Chart20.01.0927Floor Plan Layout25.01.0928Characteristics Matrix28.01.0929Process Failure Mode & Effects Analysis (PFMEA)05.02.0930Pre-launch Control Plan10.02.0931Process Instructions15.02.0932Measurement System Analysis Plan20.02.0933Preliminary Process Capability Study Plan20.02.0934Packaging Specifications28.02.09Process & Product Validation35Production Trial Run (Run @ Rate)15.03.0836Measurement Systems Evaluation20.03.0937Preliminary Process Capability Study20.03.0938Production Part Approval Process (PPAP)25.03.0939Production Validation TestingNA40Packaging Evaluation25.03.0941Production Control Plan25.03.0942Quality Planning Sign-Off & Mgmt. Support30.03.09(Supplier Document and Process Review)Feedback, Assessment & Customer Approval44Customer Satisfaction45Delivery & ServiceAdditional Program Specific Items:48Program TimlineSupplier Team Members / Position / Telephone NumberCustomer Representative / Position / Telephone NumberGreen = On Schedule / Minor IssuesRed = Must Notify Customer

&L&8LN/TS/F-15 ( 00 200303 )

CIR (2)Customer Input Requirements- Lear Automotive India Pvt. Ltd.Date (Org) :__________17.10.08Part No. :____________________L0206690AAChange Letter : _____Part Name :______________________ASM, ADJUSTER - 4 WAY MANUAL, CENTER, HEIGHT ADJUSTMENT,BS DR,RHDRev.No.00Supplier : __________________________________________Duroshox Technologies Pvt. LtdEN Ref.No. : ________________Rev.Date:-17.10.08Supplier Code :__________________Lear RequirementsExistingTargets / RequirementsRemarksFunctional RequirementsAs per SORQuality TargetsWarranty Targets ( R/1000)16R/1000 @ 12 MISPPM at LearDATE OF DATA COLLECTION :-UPPER LIMITLOWER LIMITOPERATION :-SUPPLIER NAMEPART NAMEMACHINE :-21602140MEASUREMENT SYSTEM :-MATERIAL :-UNITS :-Gms.LEAST COUNT :-Sample group12345678910111213141516171819202122232425Sample no.X12150.02153.02150.02152.02154.02148.02149.02151.02150.02150.02149.02152.02153.02153.02151.02153.02148.02150.02149.02152.02151.02152.02155.02150.02148.00X22150.02152.02150.02153.02150.02152.02149.02148.02151.02154.02152.02153.02154.02152.02149.02149.02152.02148.02154.02153.02155.02150.02152.02149.02149.029729.711.69291338580.9744094488X32149.02153.02148.02148.02150.02147.02153.02149.02148.02150.02152.02153.02149.02154.02153.02152.02148.02152.02154.02151.02152.02152.02153.02153.02153.04304316.92913385831.4107611549X42152.02149.02149.02150.02153.02152.02151.02153.02150.02149.02153.02149.02149.02150.02154.02150.02149.02148.02149.02149.02150.02151.02150.02154.02150.0197.95089590181.3746589993X52148.02149.02153.02150.02154.02149.02150.02153.02152.02154.02150.02148.02152.02150.02150.02153.02152.02150.02154.02153.02150.02147.02150.02152.02152.0X bar2149.82151.22150.02150.62152.22149.62150.42150.82150.22151.42151.22151.02151.42151.82151.42151.42149.82149.62152.02151.62151.62150.42152.02151.62150.4R4.04.05.05.04.05.04.05.04.05.04.05.05.04.05.04.04.04.05.04.05.05.05.05.05.0Short Term process capability ResultsREMARKS :-100Grand X bar=2150.936Average of all sample readings1.9680193088R bar=4.560Average of indivisual ranges0.869308257Sigma(N)=1.957R bar/d2 = R bar/2.332151.8Sigma(N-1)=1.983Std. Dev. For SamplesUCLx=2153.581Grand X bar + (A2xR bar)2153.58082150.067LCLx=2148.291Grand X bar - (A2xR bar)2148.2912(where A2 = 0.58 for 5 samples)UCLr=9.622R bar x D49.6216(where D4 = 2.11 )LCLr=0.000--Cp=1.703(USL-LSL) / (6xSigma)Pp=1.681(USL-LSL) / (6xSigma)Ppk-11.52(USL-Xbar) / (3xSigma)Ppk-21.84(Xbar-LSL) / (3xSigma)Ppk=1.52(Long Term Preliminary Process Capability)PREPARED BYAPPROVED BYRECEIVED BYUclx2153.582153.5821542154215421542154215421542154215421542154215421542154215421542154215421542154215421542154X bar2149.82151.22150.02150.62152.22149.62150.42150.82150.22151.42151.22151.02151.42151.82151.42151.42149.82149.62152.02151.62151.62150.42152.02151.62150.4LCLx2148214821482148214821482148214821482148214821482148214821482148214821482148214821482148214821482148Nom. X2151215121512151215121512151215121512151215121512151215121512151215121512151215121512151215121512151UCLr10101010101010101010101010101010101010101010101010RANGE4.004.005.005.004.005.004.005.004.005.004.005.005.004.005.004.004.004.005.004.005.005.005.005.005.00Nom.R5555555555555555555555555

&LLP/STA/F-12

SPC Variable(Pp ,Ppk)

UclxX barLCLxNom. XSample group --->X barXbar Chart

SPC Variable(Cp,Cpk)

UCL-RR-barR Mean

SPC softwareSTATISTICAL PROCESS CAPABILITY ANALYSIS - FOR VARIABLE DATA(Short Term)PROJECTPART NUMBERCHARACTERISTICSPECIFICATION ->DATE OF DATA COLLECTION :-UPPER LIMITLOWER LIMITOPERATION :-SUPPLIER NAMEPART NAMEMACHINE :-21602140MEASUREMENT SYSTEM :-MATERIAL :-UNITS :-Gms.LEAST COUNT :-Sample group12345678910111213141516171819202122232425Sample no.X12150.02153.02150.02152.02154.02148.02149.02151.02150.02150.02149.02152.02153.02153.02151.02153.02148.02150.02149.02152.02151.02152.02155.02150.02148.00X22150.02152.02150.02153.02150.02152.02149.02148.02151.02154.02152.02153.02154.02152.02149.02149.02152.02148.02154.02153.02155.02150.02152.02149.02149.029729.711.69291338580.9744094488X32149.02153.02148.02148.02150.02147.02153.02149.02148.02150.02152.02153.02149.02154.02153.02152.02148.02152.02154.02151.02152.02152.02153.02153.02153.04304316.92913385831.4107611549X42152.02149.02149.02150.02153.02152.02151.02153.02150.02149.02153.02149.02149.02150.02154.02150.02149.02148.02149.02149.02150.02151.02150.02154.02150.0197.95089590181.3746589993X52148.02149.02153.02150.02154.02149.02150.02153.02152.02154.02150.02148.02152.02150.02150.02153.02152.02150.02154.02153.02150.02147.02150.02152.02152.0X bar2149.82151.22150.02150.62152.22149.62150.42150.82150.22151.42151.22151.02151.42151.82151.42151.42149.82149.62152.02151.62151.62150.42152.02151.62150.4R4.04.05.05.04.05.04.05.04.05.04.05.05.04.05.04.04.04.05.04.05.05.05.05.05.0Short Term process capability ResultsREMARKS :-100Grand X bar=2150.936Average of all sample readings1.9680193088R bar=4.560Average of indivisual ranges0.869308257Sigma(N)=1.957R bar/d2 = R bar/2.332151.8UCLx=2153.581Grand X bar + (A2xR bar)2153.58082150.067LCLx=2148.291Grand X bar - (A2xR bar)2148.2912(where A2 = 0.58 for 5 samples)UCLr=9.622R bar x D49.6216(where D4 = 2.11 )LCLr=0.000--Cp=1.703(USL-LSL) / (6xSigma)Cpk-11.54(USL-Xbar) / (3xSigma)Cpk-21.86(Xbar-LSL) / (3xSigma)Cpk=1.54(Short Term Preliminary Process Capability)PREPARED BYAPPROVED BYRECEIVED BYUclx2153.582153.5821542154215421542154215421542154215421542154215421542154215421542154215421542154215421542154X bar2149.82151.22150.02150.62152.22149.62150.42150.82150.22151.42151.22151.02151.42151.82151.42151.42149.82149.62152.02151.62151.62150.42152.02151.62150.4LCLx2148214821482148214821482148214821482148214821482148214821482148214821482148214821482148214821482148Nom. X215121512

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