xii Contents
Key to Successful MSA ...........................................................................253
Possible Causes for Bias .........................................................................254
Possible Issues with Linearity ............................................................... 254
References .....................................................................................................254
Selected Bibliography .................................................................................. 255
17. Supplier’s Perspective of APQP...............................................................257
Overview .......................................................................................................257
APQP Initiatives ...........................................................................................258
APQP Reporting ..........................................................................................259
Fundamental Elements of APQP ............................................................... 260
Risk Assessment ..........................................................................................262
Control Plans ................................................................................................ 263
Supplement K ...............................................................................................263
References .....................................................................................................275
18. Supplier’s Perspective on the PPAP ........................................................ 277
Overview .......................................................................................................277
PPAP Submission Levels and Approvals ................................................. 281
Flow of Verication ......................................................................................282
Capacity Analysis ........................................................................................283
Capacity Report ............................................................................................285
Misconceptions about PPAP .......................................................................285
Actual Requirements ...................................................................................286
Key Clarications for PPAP ........................................................................286
References .....................................................................................................287
Selected Bibliography .................................................................................. 288
19. Capacity Analysis ....................................................................................... 289
Overview .......................................................................................................289
Goal of Capacity ...........................................................................................289
Environment for Capacity Planning .........................................................291
Overall Equipment Effectiveness (OEE) ................................................... 293
Evaluating the OEE ......................................................................................294
Some Specic Actions for Improving OEE ..............................................295
Improving Demonstrated OEE .............................................................295
Some Specic Improvements on the Components of OEE .................... 296
For Availability ........................................................................................296
For Performance Efciency ....................................................................296
For Quality Rate ...................................................................................... 296
Demonstrated OEE ...................................................................................... 296
Enablers to Improve the Demonstrated OEE ...........................................298
Other Enablers .........................................................................................298
xiiiContents
Analyze Results and Implement Actions ............................................ 298
Required OEE ...............................................................................................298
Improving Required OEE ........................................................................... 299
Shared Loading Analysis ...........................................................................299
Total Allocation ............................................................................................ 300
Reaction and Plan Expectations ................................................................300
Capacity Information Maintenance ..........................................................301
Thought Starters to Improve Supplier Capacity Volume ....................... 302
References .....................................................................................................304
20. Geometric Dimensioning and Tolerancing (GD&T) ..........................305
Overview .......................................................................................................305
Language of GD&T ......................................................................................306
Types of Drawings ....................................................................................... 313
Title Block and Notes ................................................................................... 314
Diamond P and D Requirements .............................................................. 315
Tolerance Types ............................................................................................ 316
Basic Dimensions .................................................................................... 317
Line Conventions on Production Drawings ....................................... 319
Feature of Size (FoS) .................................................................................... 319
Maximum Material Condition (MMC) ..................................................... 321
Least Material Condition (LMC) ................................................................322
Virtual Condition .........................................................................................322
Datum and Target Datum Symbols ..........................................................323
Tolerance Modifying Symbols ................................................................... 323
Independency ............................................................................................... 323
Feature Control Frames (FCF) ....................................................................323
Datum ............................................................................................................324
Datum Targets ......................................................................................... 325
Things to Remember: Datums .............................................................. 326
Things to Remember: Form ...................................................................326
Orientation ....................................................................................................327
Rules Applied to Orientation ................................................................327
Things to Remember: Orientation ........................................................ 327
Projected Tolerance Zone (
P
) ..............................................................328
Things to Remember: Position ..............................................................328
Prole Controls ............................................................................................329
Circle U Modier (
U
) ...........................................................................329
Things to Remember: Prole .................................................................329
Coaxial Controls Overview ........................................................................ 330
Key Elements to Review GD&T by Asking the Following
Questions .................................................................................................. 330
MMC (M) and LMC (L) .......................................................................... 332
MMC (M) ............................................................................................. 332
xiv Contents
LMC (L) ................................................................................................332
Regardless of Feature Size (RFS) ..........................................................332
Features That Require Datum ............................................................... 333
References .....................................................................................................334
Selected Bibliography .................................................................................. 334
21. 8D ................................................................................................................... 335
Overview .......................................................................................................335
8D Application Criteria ............................................................................... 336
D0: Prepare for the Problem-Solving Process ..........................................337
D1: Establish the Team: Process Flow .......................................................339
Team Composition ..................................................................................340
Champion ............................................................................................ 340
Team Members ...................................................................................341
Team Leader ........................................................................................341
Recorder ...............................................................................................341
Facilitator ............................................................................................. 341
D1: Process Guidelines ...........................................................................342
Warming Up ............................................................................................343
Membership ............................................................................................. 343
D2: Describe the Problem ...........................................................................344
D2: Process Guidelines ........................................................................... 346
How to Develop a Problem Description .............................................. 348
D2: Evaluating Questions ......................................................................351
D3: Develop the Interim Containment Action (ICA) ..............................352
D3: Process Guidelines ........................................................................... 353
D3: Evaluating Questions ......................................................................354
D4: Dene and Verify Root Cause and Escape Point .............................355
Determining Root Cause .......................................................................356
D4: Guidelines .........................................................................................356
D4: Evaluating Questions ......................................................................357
Generic Simple Root-Cause Analysis ...................................................358
Determination of the Root Cause .........................................................358
Verify Root Cause ................................................................................... 361
Helpful Supplemental Tools .................................................................. 361
D5: Choose and Verify PCAs for Root Cause and Escape Point ...........362
D5: Process Guidelines ...........................................................................362
D5: Evaluating Questions ......................................................................363
D6: Implement and Validate PCAs ............................................................364
Removing the ICA ..................................................................................365
D6: Process Guidelines ...........................................................................365
D6: Evaluating Questions ......................................................................366
D7: Prevent Recurrence ............................................................................... 367
D7: Process Guidelines ........................................................................... 369
xvContents
D7: Evaluating Questions .......................................................................371
D8: Recognize Team and Individual Contributions ............................... 372
D8: Process Guidelines ........................................................................... 373
D8: Evaluating Questions ...................................................................... 374
8D Summary Evaluation .............................................................................375
Prepare for the 8D Process ..................................................................... 375
Establish the Team ..................................................................................375
Describe the Problem .............................................................................375
Develop the Interim Containment Action ........................................... 376
Dene and Verify Root Cause and Escape Point ................................ 376
Choose and Verify Permanent Corrective Actions for Root
Cause and Escape Point .........................................................................377
Implement and Verify Permanent Corrective Actions ......................377
Prevent Recurrence ................................................................................. 378
Recognize Team and Individual Contributions ................................. 378
8D Success Factors ....................................................................................... 378
References .....................................................................................................379
Selected Bibliography .................................................................................. 379
2 2. Mi s ce ll a ne ou s .............................................................................................. 381
Overview ....................................................................................................... 381
Typical Total Production System (TPS) .....................................................381
Ford’s Approach to TPS ...............................................................................382
Toyota Production System (TPS) ................................................................384
Suppliers and TPS ................................................................................... 385
Suggested Implementation of a Production System ...............................386
Production System Model Based on an American Engine Plant ..........387
Supplier Request for Engineering Approval (SREA) ..............................388
Service Unique Products ........................................................................390
Temporary SREA .....................................................................................390
Supplier Risks for Not Following an SREA .........................................391
Warranty ....................................................................................................... 391
Weibull Distribution ....................................................................................393
FMEA .............................................................................................................397
Six Sigma .......................................................................................................398
Six Sigma Methodology ......................................................................... 399
DMAIC .................................................................................................399
DMADV ...............................................................................................400
Levels of Six Sigma Mastery .................................................................. 401
Systems Engineering ................................................................................... 402
Value Engineering .......................................................................................404
References .....................................................................................................406
Selected Bibliography .................................................................................. 407
xvi Contents
Epilogue ............................................................................................................... 409
Glossary ............................................................................................................... 415
Appendix I: Typical Detailed Expectation List of a Site Assessment
by the Customer to the Supplier’s Facility ....................................................439
Appendix II: PPAP Checklist ..........................................................................449
Appendix III: Mistake Proong .....................................................................453
Appendix IV: Preparation of an Audit ..........................................................463
Appendix V: Miscellaneous Items .................................................................505
Selected Bibliography ....................................................................................... 601
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