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Review customer
requirements/specification and
initiate FMEA
3./20. Is

Note #s appearing in shapes in the process flow on the left

are references to the Requirements/Guidelines listed below:

10./13. Conduct
measurement systems




6./16. Do
MSA results meet

3. Establish control plan noting

the characteristic and process
parameters / product tolerances
5./18. Determine methods for
evaluation/measurement, list
technique & any measurement
device(s) selected

15. If a
device can it
1/10 of expected

ISO/TS 16949:2009 Links to Core Tools

4./13. Select samples from

Significant Product Run

11. PerformYes


12. Conduct material/

performance tests


13./21. Is
capable or customer
approved corrective
action plan?

5./6. Note measuring devices

under evaluation/measurement
technique in control plan

7./8. Select qualified internal/

external laboratory for PPAP


14. Identify one or more of

the parts as a "master
sample" and retain


7./8. Is
the inspection/test
on the Laboratory's

4. Confirm PPAP
requirements have been



12. Conduct material/

performance tests


1. Agree/confirm process
capability or performance
requirements w/customer

13. Has
the level of initial
process capability or
performance been

13. Schedule significant

production run and conduct
initial process study:
Ppk - Special causes of
variation present and/or less
than 100 readings from
consecutive parts.
Cpk - No special causes of
variation and at least 100
individual samples.
Notify customer of unstable
processes that exist or if not
enough data available (<100).



9. Verify
on-going process


5. Is
unstable or noncapable?


5. Initiate reaction plan,

develop corrective action
plan, review with customer
if required

**ISO/TS 16949:2009** (requirements)

1. The organization shall demonstrate conformity to customer
requirements for designation, documentation and control of special
2. - development and review of FMEAs, including actions to
reduce potential risks
3. The organization shall identify special characteristics and include
all special characteristics in the control plan.
4. The organization shall conform with a product approval
procedure recognized by the customer. This product and manufacturing
process procedure shall be applied to suppliers.
5. The organization shall - develop control plans (see Annex A)
- have a control plan for pre-launch and production that takes
into account the design FMEA and manufacturing process FMEA outputs
- list controls used for manufacturing process control
- include methods for monitoring of control exercised over
special characteristics defined by both the customer and the organization
- initiate the specified reaction plan when the process
becomes unstable or not statistically capable. Update and review control
plans when change occurs or FMEA (see 7.1.4).
6. 7.6.1 Statistical studies shall be conducted for each type of measuring
and test equipment system referenced in the control plan. Methods and
acceptance criteria shall conform to those in customer reference
manuals or be otherwise approved by the customer.
7. The organization's internal laboratory shall have a laboratory
scope that includes its capability to perform the required inspection, test
or calibration services and the laboratory scope shall be included in the
QMS documentation.
8. External/commercial/independent laboratory facilities shall have
a defined laboratory scope that includes its capability to perform the
required inspection, test or calibration services and either provide
evidence that it is acceptable to the customer or that it is accredited to
ISO/IEC 17025 or national equivalent.
9. The organization shall maintain manufacturing process capability
or performance as specified by the customer part approval process
**PPAP** Fourth Edition (requirements)
10. 2.2.8 The organization shall have applicable Measurement System
Analysis studies, e.g., gage R&R, bias, linearity, stability, .
11. 2.2.9 The organization shall provide evidence that dimensional
verifications indicate compliance with specified requirements.
12. 2.2.10 The organization shall have records of material and/or
performance test results for tests specified on the design record .
13. The level of initial process capability or performance shall be
determined to be acceptable prior to submission for all special
characteristics The organization shall obtain customer concurrence
on the index for estimating initial process capability prior to submission.
14. 2.2.15 The organization shall retain a master sample for the same
period as the production part approval records .
**MSA** Fourth Edition (guidelines)
15. Pg 74 The instrument should have a discrimination that allows onetenth of the expected process variation of the characteristic to be read.
16. Pg 78 Over 30% error - considered not acceptable.
**APQP** Second Edition (guidelines)
17. Pg 34 The specified monitoring and measuring devices and methods
should be used to check the control plan identified characteristics to
engineering specification and be subjected to measurement system
evaluation during or prior to the production trial run.
18. Pg 53 Evaluation measurement technique. This could include gages,
fixtures, tools and/or test equipment required to measure the part/
process/manufacturing equipment.
**FMEA** Fourth Edition (guidelines)
19. Pg 2
FMEA is an analytical methodology used to ensure that potential
problems have been considered and addressed throughout the product
and process development process (APQP).
20. Pg 91 Where a special characteristic is identified with a severity of 9 or
10 in the PFMEA, the design responsible engineer should be notified
since this may affect the engineering documents.
**SPC** Second Edition (guidelines)
21. Pg 20 To be acceptable, the process must be in a state of statistical
control and the capability (common cause variation) must be less than
the tolerance.

PPAP and the APQP, FMEA, MSA, SPC Reference Manuals are Copyright
of Chrysler Corporation, Ford Motor Company, General Motors Corporation

File: CoreTls.vsd Rev. 09/01/2013