PPAP

PPAP HEADER INFORMATION FORM PART FAMILY
COVER R/L MAIN PIPE

SIDE
PART NUMBER: 64460/70-KWBF-9203 (KVLP)
CUSTOMER PART NUMBER: 64460/70-KWBF-9203

PAP NUMBER
PART NAME: COVER R/L LOWER 01-ENG/PAP-KWBF-AHM
CUSTOMER REV. LEVEL: NF REV DATE: 11 Januari 2008
SUPPLIER NAME: PT. YASUNLI AUP.
CUSTOMER NAME: PT. Astra Honda Motor
LAST MODIFIED BY: EKO W.P. DATE: 28 Juli 2008

No. Doc. :
List PPAP Revision :
Logo Perusahaan Page :
Part Name : Customer :
COVER R/L LOWER PT. Astra Honda Motor
Part Number : Location :
64460/70-KWBF-9203 Tanggerang
Date : Level PPAP :
28 Juli 2008 1 2 3 4 5
Item Report Document

1 Design Records of Saleable Product Drawing Part Cover Rear Handle KWBF
2 Engineering Change Documents NA
3 Customer Engineering Approval NA
4 Design FMEA NA
5 Proccess Flow Diagram PQCS Hal1 Part Cover Rear Handle KWBF
6 Process FMEA PFMEA Part Cover Rear Handle KWBF
7 Dimensional Result Data Ukur Drawing Part Cover Rear Handle KWBF
8 Material/Performance Test Result
a. COA Material COA Material ABS 10JK2A (Techno Polymer)
b. COA Master Batch COA Master Batch JB 1112-30 Grey (PT. DIC Astra Chem)
9 Initial process study Initial Process Study Part Cover Rear Handle KWBF
10 Measurement System Analysis Study MSA Part Cover Rear Handle KWBF
11 Qualified laboratory documentation NA
12 Control Plan PQCS Part Cover Rear Handle KWBF
13 Part Submission Warrant NA
14 Appearance Approval Report NA
15 Sample Product Sample Trial Part Cover Rear Handle KWBF
16 Master Sample Sample Approval Part Cover Rear Handle KWBF (AHM)
17 Checking Aids Assy Switch
18 Record of Compliance
a. Trial (PP) Form Initial Part for Project (AHM) & Part Inspection Sheet
b. Mass Production Part Inspection Sheet Part Cover Rear Handle KWBF
19 Others Requirement Standard Operation Procedure Part Cover Rear Handle KWBF
Packing Standard Part Cover Rear Handle KWBF
Setting of Parameter Part Cover Rear Handle KWBF
Comments:
Reviewed & Approved

TIMING CHART DESIGN PROCESS
PART NUMBER : 64460/70-KWBF-9203 CUSTOMER : AHM REVISION : REVIEW BY : EKO W.P.
PART NAME : COVER R/L LOWER DATE :11 Januari 2008 REVIEW DATE : 28 Juli 2008
2007 2008
No. ACTIVITY PIC SEPTEMBER OKTOBER NOVEMBER DESEMBER JANUARI '08 FEBRUARI MARET APRIL MAY JUNI JULI AGUSTUS SEPTEMBER REMARK
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
I MANUFACTURING PROCESS DESIGN INPUT
1.1 Product Design Output Data ENG
1.2 Targets:
1.2.1 Productivity PPC
1.2.2 Process Capability QA
1.2.3 Cost COST
1.2.4 Laju Produksi PPC
1.2.5 Initial and/or Projected Order Quantity COST/ENG
1.3 Customer Requirements ENG
1.4 Experience from Previous Development
1.4.1 Similar Process Flow Chart ENG
1.4.2 Special Notice (lesson learned,things gone wrong) ENG/QC
1.5 Error Proofing Method ENG
1.6 Process Special Characteristics QC
1.7 Others:
1.7.1 Process Related Training INJ/ENG
1.8 Review ENG
II MANUFACTURING PROCESS DESIGN OUTPUT

2.1.a. Speciafication & Drawing ENG
2.1.b. Completion of Tooling (NA) TEAM
2.2 Manufacturing Process Flow Chart/Layout TEAM
2.3 Process FMEA TEAM
2.4 Pre-launch Control Plan TEAM
2.5 WI/SOP INJ
2.6 Process Approval Acceptance Criteria ENG
2.7 Production Control Plan TEAM
2.8 Trial Run TEAM
2.9 Data for:
2.9.1 Process Capability QC
2.9.2 Reliability MTN
2.9.3 Maintainability MTN
2.9.4 Measurability ENG
2.10 Methods of Rapid Detection & Feedback of
Product/Manufacturing Process Nonconformities TEAM
2.11 Review TEAM
III FINAL REVIEW

Review TEAM
: Schedule FM-30/ENG-04-08.Rev.00
: Actual
TIMMING CHART DESIGN PROCESS
Part Number : 64460/70-KWBF-9202 Part Name: Cover R/L Lower Customer: AHM No:
IV. MANUFACTURING PROCESS DESIGN INPUT V. MANUFACTURING PROCESS DESIGN OUTPUT VI. VERIFICATION/VALIDATION
No Item/Requirements C/R/I* Reference/Target No Item/Where Specified Reference Result Remark
1 Product Design Output Data C Drawing Cover R/L Lower KWB File Model KWB Q-16 DE/Eng-Y1/DRW-AHM/057 Open tunggu drw maspro
2 Targets:
Laporan Detail Produksi Injection Bulan Desember PPC2 / Local D / Winarti File / Produksi / Laporan Detail
- Productivity I FM-05/Inject-12-05-Rev.03 Close
2007 (Cover R/L Main Pipe Side KVLP) Injection / Tahun 2007 (Cover R/L Main Pipe Side KVLP)
- Process Capability I Instruksi Kerja PPAP File Instruksi Kerja Eng C1-5 IK/ENG-12
- Cost I Quotation (Cover R/L Main Pipe Side KVLP) File Quotation AHM KVLP Master List Quotation AHM KVLP Close
- Laju Produksi I Data Operation Molding Injection AHM (Cover R/L d on ppc4/data operation molding/tahun 2007 (Cover R/L 07/Inject-01-07-Rev.02(KVLP, No 6&7)
Main Pipe Side KVLP) Main Pipe Side KVLP) Close
- Initial and/or Projected Order Quantity C Surat Penawaran Pembuatan Part File Document & Letter In-Out File Q-13 (461/PPP/PU/IX/07) Close
3 Customer Requirements C/I QCDD Activity / Event By Part KWB File Model KWB - Close Form Dari Custumer
Close
4 Experience from previous development
- Similar Process Flow Chart I PQCS (Cover R/L Main Pipe Side KVLP) File Model KVLP 07-ENG-YAUP/P.QC.S-KVLP-AHM Close
Master List Quality Performance AHM
- Special Notice (lesson learned, I Quality Status AHM Quality Performance AHM (FM38/QA-01-08-Rev.00) Close
things gone wrong) (Cover R/L Main Pipe Side KVLP)
5 Error Proofing Method C - Close
6 Process Special Characteristics C PQCS (Cover R/L Main Pipe Side KVLP) File Model KVLP 07-ENG-YAUP/P.QC.S-KVLP-AHM Close
7 Others:
- Process Related Training I Drawing Cover R/L Lower KWB File Model KWB Q-16 DE/Eng-Y1/DRW-AHM/057 Open tunggu drw maspro
(e.g. customer specified definition & symbols)
06/SM/Eng-Y1/KWBF/AHM & DE/Eng-

1. a. Specification & Drawing Open tunggu drw maspro
8 Manufacturing Process Design Input Review Y1/DRW-AHM/057
b. Completion of tooling - Open Mould Dari PT. AHM
Design Review Results: 2 Manufacturing Process Flow Chart/Layout 01-ENG-YAUP/P.QC.S-KWB-AHM Open masih dalam bentuk draft
Part Spesifikasi mengacu ke Part CMPS R/L KVLP 3 Process FMEA 01-ENG-YAUP/PFMEA-KWB-AHM Open masih dalam bentuk draft
-Mesin 4 Pre-launch Control Plan 01-ENG-YAUP/P.QC.S-KWB-AHM Open masih dalam bentuk draft
-CT 5 WI/ SOP IK-4.02-AHM-136 Open masih dalam bentuk draft
-Berat Runner 6 Process Approval Acceptance Criteria AS-AHM-KWB-01 Open masih dalam bentuk draft
7 Production Control Plan 01-ENG-YAUP/P.QC.S-KWB-AHM Open masih dalam bentuk draft
8 Trial Run - Open masih dalam bentuk draft
9 Data for:
- Process Capability FM-37/ENG-06-08.Rev.00 Open
- Reliability - Open
- Maintainability - Open
- Measurability FM-38/ENG-06-08.Rev.00 Open
10 Methods of Rapid Detection & Feedback of - -

Product/Manufacturing Process Nonconformities
11 Manufacturing Process Design Output Review Design Review Results:
Dokumentasi dan mampu telusur dokumen sudah siap, namun dokumen-
Design Review Results: dokumen tersebut harus diperbarui setiap kali ada event trial, untuk
Dokumentasi dan mampu telusur dokumen sudah siap, namun dokumen- melengkapi isi dari dokumen tersebut (dokumen baru berupa draft)
dokumen tersebut harus diperbarui setiap kali ada event trial, untuk
melengkapi isi dari dokumen tersebut (dokumen baru berupa draft) Design review results conclusion: (tandai √ pada kotak yang sesuai)
…………………………………….……………………………………………… √ Continue as per Programme Timing Chart
…………………………………….……………………………………………… Back to Process Design Output Stage
…………………………………….……………………………………………… Back to Process Design Input Stage
Design review results conclusion: (tandai √ pada kotak yang sesuai) Back to Product Design Stage
√ To continue with Process Design Output Stage Design review results conclusion: (tandai √ pada kotak yang sesuai) Request customer approval for change in specification
Back to Process Design Input Stage √ To continue with Verification/Validation Back to Process Design Input Stage llll Request approved by customer
Back to Product Design Stage Back to Process Design Output Stage Back to Product Design Stage Request not approved by cu
Reviewed by: Reviewed by:
Note: * C = Customer
R = Regulatory & Statutory
(Maman K) I = In-house (Maman K) (Maman K)
Tanggal: 11 Januari 2008 Tanggal: 13 Februari 2008 Tanggal: 17 Maret 2008
No. Doc. : FM-29/ENG-04-08.Rev.00
Addtional
Revision : 00 / 07 - 04 - 2008
Engineering Change
Page : 1 of 1
Part Number Part Name Engineering Drawing Change Level

64460/70-KWBF-9203 COVER R/L LOWER
Collection Date Collected by Engineering Change Date
VALID ON
CHANGE DOC # TYPE OF CHANGE DOCUMENT DESCRIPTION / NATURE OF CHANGE DOCUMENT OR BEFORE
(ECN / MANDATORY)
.
M-29/ENG-04-08.Rev.00
/ 07 - 04 - 2008
Drawing Change Level
Change Date
EXPIRATION
DATE (PERMIT)
PT. Yasunli Abadi Utama Plastic MODEL KODE REGISTER
Production Engineering
KWB
HS HA HB Q NF
COVER R/L LOWER PROSES Q

No Dok : 01-ENG-YAUP/P.QC.S-KWB-AHM
No Rev : 00 Dokumen ini adalah dokumen kualitas yang akan dijadikan
64460/70-KWBF-9203
DIAGRAM FLOW PROSES
NO
Natural Grey
1
A A B A B
1 1
Receiving 1 1 Receiving 1 Receiving
2 2
Incoming Inspection2 2 Incoming Inspection
2 Incoming Inspection
Storage (WH) Storage (WH) Storage (WH)

3 3 3 3 3
Prepare Mixing Mixing

4 Material 4 4
Material Material
Injection Moulding Injection Moulding Injection Moulding

5 Process 5 5
Process Process
Quality Quality Quality

6 Inspection 6 6
Inspection Inspection
Storage Storage Storage

7 (WH) 7 (WH) 7 (WH)
Out Going Out Going Out Going

8 Inspection 8 8
Inspection Inspection
9 Delivery to 9 Delivery
9 to Delivery to
AHM AHM AHM
09
08
07
LAMBANG DAN FLOW PROCESS
06
== Proses == WIP
WIP Stock
Stock Station
Station 05
04
== Quality Inspection == Quantity
Quantity & Quality Inspection 03
== Process
Process & Quality Inspection
Inspection 02
== Quantity
Quantity Inspection
Inspection
01
== Flow Process == Process
Process & Quantity Inspection 00
== Storage
Storage == SHIPMENT
SHIPMENT / DELIVERY Rev
FM-24a/ENG 12-05 Rev.01

PREPARED BY : APPROVED BY :
ROSES QC SHEET
PT. YASUNLI AUP PT. ASTRA HONDA MOTO
Approved Checked Prepared Approved
h dokumen kualitas yang akan dijadikan referensi AUDIT maupun VERIFIKASI KUALITAS
Sukiran Heri S. Maman K.
IDENTIFIKASI INPUT PROSES

SOURCING
PART NAME PROCESS NAMA MAKER / VENDOR
In PLANT Out PLANT
Cover R/L Lower Injection PT. Yasunli AUP
A. ABS 10 JK2A (Original) Techno Polymer Co., Ltd. (PT. Sojitz)
B. JB 1112-30 Grey (1%) PT. DIC Astra Chemical
CATATAN PENGENDALIAN DOKUMEN

17/06/08 Penerbitan Pertama Heri S. Maman K.
Approved Prepared Approved
Tgl/Bln/Thn Catatan Perubahan
Penanggung Jawab AHM - Approval
APPROVED BY :
PT. ASTRA HONDA MOTOR PAGE

Checked Checked
1/3
NAMA MAKER / VENDOR
Co., Ltd. (PT. Sojitz)

Approved Checked
AHM - Approval
PROCESS FAILURE MODE AND EFFECT ANALYSIS Page : 15 Of 116
(PFMEA)
CUSTOMER : PT. ASTRA HONDA MOTOR CORE TEAM : ENGINEERING, PPC, QA, TECHNISI, MMMC
PART NAME : COVER R/L LOWER PREPARED BY : EKO W. P.
PART NO. : 64460/70-KWBF-9202 NO : 01-ENG-YAUP/PFMEA-KWB-AHM PROCESS RESPONSIBIL: ENGINEERING, PPC, QA, TECHNISI, MMMC
MODEL : KWB CLASS : NF KEY DATE : -
YEAR : 2008 FMEA DATE : 11-03-2008 REV : 00
Process Function / Potential Causes Responsibility & Target Action Result

Potential Failure Mode Potential Effects of Failure S Class O Current Process Control D RPN Action Plan
Requirement Mechanisms of Failure Completion Date Action Taken S O D RPN
1. Receiving Material
a. ABS 10JK2A Kemasan tidak standar Material Berceceran - Hasil Cek Bea Cukai (D) pengecekan visual
kemasan
5 7 35
(Material Import) (P) Instruksi kerja
penerimaan material
1 - Proses Penurunan (D) pengecekan visual
kemasan
Material dari Container 5 (P) Instruksi kerja 7 35
penerimaan material
(Zak Jatuh Ke Tanah)
Jenis material salah - Salah label material 1 (D) pengecekan visual 7 7

kemasan
1 NF
- Salah surat jalan 4 (P) Instruksi kerja 7 28
penerimaan material
b. MB JB 1112-30 Grey Kemasan tidak standar Material Berceceran - Hasil Cek Bea Cukai (D) pengecekan visual
kemasan
5 7 35
(Material Import) (P) Instruksi kerja
penerimaan material
1 - Proses Penurunan (D) pengecekan visual
kemasan
Material dari Container 5 (P) Instruksi kerja 7 35
penerimaan material
(Zak Jatuh Ke Tanah)
Jenis masterbatch salah - Salah label masterbatch 1 (D) pengecekan visual 7 7

kemasan
1 NF
- Salah surat jalan 4 (P) Instruksi kerja 7 28
penerimaan material
2. Incoming Inspection
a. ABS 10JK2A - Material Tidak - Produk Tidak Sesuai (P) instruksi kerja
1 NF - Inspector terlupa 1 pengecekan material 7 7
di cek visual Standard (Appearance)
- Berat tidak sesuai (D) pengecekan visual

kemasan
- Salah surat jalan 1 7 7
1 (P) instruksi kerja
penerimaan material
- Timbangan tidak akurat 1 (P) instruksi kerja 7 7
penerimaan material
b. MB JB 1112-30 Grey - Sample Master Batch - Produk Tidak Sesuai - Colour Chip Tidak (D) Sample Warna
1 7 7
tidak dicek dengan Standard (Warna) 1 NF Sesuai Standard (P) COA Material
colormetric - Hanya pengecekan visual (P) Instruksi Kerja

1 7 7
pengecekan colorcip
(D) pengecekan visual
kemasan
- Berat tidak sesuai
(P) instruksi kerja
- Salah surat jalan 1 penerimaan material 7 7
1
(P) instruksi kerja
penerimaan material
- Timbangan tidak akurat 2 (P) instruksi kerja 7 14
penerimaan material
3. Storage Kemasan sobek Material Berceceran - Material Jatuh (P) Instruksi Kerja
1 (Penumpukan Terlalu 1 Penyimpanan Material 7 7
Tinggi) (Standard Penumpukan)

(PFMEA)

4. Mixing Material
- Material Tercampur - Produk Tidak Sesuai - Mixer Digunakan Untuk - Instruksi Kerja
Material Lain Standard (Appearance) Berbagai Material 1 Penyediaan Material 7 7
Untuk Produksi
- Pencucian Hopper Di - Instruksi Kerja
1
Mesin Kurang Bersih 3 Penyediaan Material 7 21
Untuk Produksi
- Komposisi Material & - Produk Tidak Sesuai - Komposisi MB Tidak - Timbangan

3 7 21
MB Tidak Sesuai Std Standard (Warna) Sesuai Standard
5. Injection Moulding
Process - Produk Flow Mark - Visual Produk Tidak 1 Speed Rendah 10 (P) Standard Setting 7 70 - Setting Speed TEAM - TRIAL EVENT PP2
- Produk Belang Maksimal 1 Back Press Rendah 10 (P) Standard Setting 7 70 - Setting Back Press TEAM - TRIAL EVENT PP2
- Produk Hangus - Speed Tinggi 10 (P) Standard Setting 7 70 - Setting Speed TEAM - TRIAL EVENT PP2
- Pressure Tinggi 10 (P) Standard Setting 7 70 - Setting Pressure TEAM - TRIAL EVENT PP2
1 - Holding Press Tinggi 10 (P) Standard Setting 7 70 - Setting Holding Press TEAM - TRIAL EVENT PP2
- Tidak Ada Air Vent (P) Standard Setting - Dibuatkan Air Vent TEAM - TRIAL EVENT PP2
10 7 70
Pada Mold
- Produk Silver - Visual Produk Tidak - Back Press Tinggi 10 (P) Standard Setting 7 70 - Setting Back Press TEAM - TRIAL EVENT PP2
Maksimal - Suhu Barel Rendah 10 (P) Standard Setting 7 70 - Setting Suhu Barel TEAM - TRIAL EVENT PP2
1
- Cooling System Tidak (P) Standard Setting - Setting Cooling System TEAM - TRIAL EVENT PP2
10 7 70
Sesuai (Material ABS) (Material ABS)
- Produk Sink Mark - Visual Produk Tidak - Holding Pressure rendah 10 (P) Standard Setting 7 70 - Setting Holding Press TEAM - TRIAL EVENT PP2
Area surface Maksimal - Injection Time Rendah 10 (P) Standard Setting 7 70 - Setting Injection Time TEAM - TRIAL EVENT PP2
Lubang Screw / Rib - Cooling Time Rendah 10 (P) Standard Setting 7 70 - Setting Cooling Time TEAM - TRIAL EVENT PP2
1
- Tebal Lubang Screw (P) Standard Setting
/ Rib Lebih Dari 3/4 10 7 70 - Cek 3D Produk TEAM - TRIAL EVENT PP2
Tebal Produk
- Produk Flash - Visual Produk Tidak - Injection time tinggi 10 (P) Standard Setting 7 70 - Setting Injection Time TEAM - TRIAL EVENT PP2
Maksimal 1 - Pressure Tinggi 10 (P) Standard Setting 7 70 - Setting Pressure TEAM - TRIAL EVENT PP2
NF
- Injection speed tinggi 10 (P) Standard Setting 7 70 - Setting Speed TEAM - TRIAL EVENT PP2
- Short material - Terjadi Masalah Ketika - Injection time rendah 10 (P) Standard Setting 7 70 - Setting Injection Time TEAM - TRIAL EVENT PP2
Assy Unit Motor 1 - Injection speed rendah 10 (P) Standard Setting 7 70 - Setting Speed TEAM - TRIAL EVENT PP2
- langkah screw rendah 10 (P) Standard Setting 7 70 - Setting Langkah Screw TEAM - TRIAL EVENT PP2
- Dimensi Diameter - Terjadi Masalah Ketika - Material Terlalu Padat 6 (P) Standard Setting 7 42
Lubang Screw Over Assy Unit Motor 1
pada area locking - Lubang flash 6 (P) Standard Setting 7 42

(PFMEA)

- Dimensi Tidak Sesuai - Terjadi Masalah Ketika - Dimensi Mold Tidak (P) Check Sheet / PIS
1 6 7 42
Standard Assy Unit Motor Sesuai Standard
6. Quality Inspection - pengecekan kurang teliti - Produk not good lolos - Pemahaman point quality (P) Check Sheet / PIS
1 6 7 42
kritis produk kurang (P) Training operator
7. Storage - Tumpukan Box - Produk Cacat (Surface) - Penumpukan Box (P) Instruksi Kerja
Roboh 1 Terlalu Tinggi 2 Penyimpanan Barang 7 14
(Standard Penumpukan)
- Penyimpanan, - Identifikasi Masalah Sulit - System FIFO Tidak (P) Instruksi Kerja
Penerimaan & Dilacak Berjalan 2 Penyimpanan Barang 7 14
1
Pengeluaran Barang (Standard Penumpukan)
Tidak Teratur
8. Out Going - Pengecekan kurang teliti - Produk not good lolos 1 - Pemahaman point quality (P) Check Sheet / PIS
6 7 42
Inspection kritis produk kurang
- Salah kirim 1 - Salah memasang label 2 (P) Check Sheet / PIS 7 14
ok produk antara kanan

dan kiri
9. Delivery Process - Salah Kirim Barang - Barang Yang Dikirim - Pengecekan Proses (P) Bon Permintaan
Tidak Sesuai Dengan 1 Naik Barang Kurang 2 Barang 7 14
Bon Permintaan Barang Teliti
FM-32/ENG-04-08.Rev.00
S (Severity) = Efek kegagalan yang berpengaruh terhadap kenyamanan pengendara dan performa kendaraan
O (Occurance) = Menentukan tingkat kejadian / seberapa sering penyebap kegagalan tsb
D (Detection) = Kemampuan sistem kontrol design dalam mendeteksi penyebap kegagalan

RPN <1/2 dari yang terbesar bagus
RPN ≥1/2 dari yang terbesar harus diperbaiki
CLASS :
HS : Tidak ada tanda-tanda kerusakan tetapi bisa mengakibatkan kecelakaan fatal sampai bisa memakan korban
HA : Ada tanda-tanda kerusakan, bisa mengakibatkan kecelakaan fatal sampai bisa memakan korban
HB : Ada tanda-tanda kerusakan, tapi tidak mengakibatkan kecelakaan fatal sampai memakan korban
Q : Standar quality tergantung drawing, visual
NF : Standar drawing ( grade ) yang harus ada di part
No. Doc. : FM-28/ENG-04-08.Rev.00
Dimention Result Rev. : 00 / 07 - 04 - 2008
Logo Perusahaan Page : 1 of 1
Company : Part Number (Company) : Part Number (Customer) :

PT. YASUNLI AUP. 64460/70-KWBF-9203 64460/70-KWBF-9202
Customer : Part Name : Dimention Result Date :
PT. AHM Cover R/L Lower
Item Dimension/ Spesification Tol. Measurement Results Ok

M-28/ENG-04-08.Rev.00
0 / 07 - 04 - 2008
(Customer) :
esult Date :
Not Ok
No. Doc. : FM-37/ENG-04-08.Rev.00
Material Test Result Rev. : 00 / 07 - 04 - 2008
Logo Perusahaan Page : 1 of 1
Supplier Part Name
Cover R/L Lower
Name of Laboratory Part Number

64460/70-KWBF-9203
Test Qty.
No. Material Spec Requirements Supplier Test Results and Test Conditions
Freq. Tested
: FM-37/ENG-04-08.Rev.00
: 00 / 07 - 04 - 2008
03
OK Not OK
Initial Process Study
LOCATION Plant Dept: ENG
PART Part number: 64460/70-KWBF-9203 Part description Cover R Lower
Drawing number 64460/70-KWBF-9203 Eng. chg. level
SPECIFICATION SPEC 2.5 PLUS 0.2
RESULT UCLX LCLX UCLR
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover R Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover R Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover R Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover R Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
PART Part number: 64460/70-KWBF-9203 Part description Cover L Lower
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover L Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover L Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover L Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
Cpk Ppk
Date
Time
Subgroup 1 2 3 4 5 6 7 8
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Date
Time
Subgroup 14 15 16 17 18 19 20 21
1
R
E 2
A
D 3
I
N 4
G
5
SUM
Average
Range
Control Chart
Graph Capability
dy
Date:
Cover L Lower
MINUS 0.0
LCLR
9 10 11 12 13
22 23 24 25
FM-33/ENG-04-08.Rev.00
FM-33/ENG-04-08.Rev.00
GR&R DATA SHEET
VARIABLE DATA RESULTS - TOTAL VARIATION
PART NUMBER / REVISION GAGE NAME APPRAISER A
64460-KWBF-9200 3 DIGITAL CALIPER EKO
PART NAME GAGE NUMBER APPRAISER B
COVER R LOWER 1044243 MULYADI
CHARACTERISTIC SPECIFICATION GAGE TYPE APPRAISER C
2.5 0 0.2 0-300 MM -
CHARACTERISTIC CLASSIFICATION TRIALS PARTS APPRAISERS
2 10 2
DERIVED RESULTS MAY NOT BE STATISTICALLY SOUND
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 2.50 2.49 2.48 2.51 2.53 2.52 2.47 2.54 2.50
2 2.51 2.50 2.49 2.52 2.53 2.52 2.48 2.53 2.50
3
AVE 2.51 2.50 2.49 2.52 2.53 2.52 2.48 2.54 2.50
R 0.01 0.01 0.01 0.01 0.00 0.00 0.01 0.01 0.00
MULYADI 1 2.50 2.49 2.49 2.51 2.54 2.51 2.47 2.54 2.50
2 2.50 2.49 2.48 2.52 2.53 2.52 2.47 2.54 2.51
3
AVE 2.50 2.49 2.49 2.52 2.54 2.52 2.47 2.54 2.51
R 0.00 0.00 0.01 0.01 0.01 0.01 0.00 0.00 0.01
1
2
3
AVE
R
PART
AVERAGE 2.50 2.49 2.49 2.52 2.53 2.52 2.47 2.54 2.50
(ra + rb + rc) / (# OF APPRAISERS) =
xDIFF = (Max x - Min x) =
* UCLR = R x D4 =
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are beyond this limit. Identify the cause and correct.
Repeat these readings using the same appraiser and unit as originally used or discard values and re-average and recalculate R and the limiting value from th
remaining observations.
NOTES:
GR&R DATA SHEET
ON VARIABLE DATA RESULTS - TOTAL VARIATION
ISER A PART NUMBER GAGE NAME APPRAISER A
64460-KWBF-9203 DIGITAL CALIPER EKO
ISER B PART NAME GAGE NUMBER APPRAISER B
DI COVER R LOWER 1044243 MULYADI
ISER C CHARACTERISTIC GAGE TYPE APPRAISER C
2.5 0-300 MM -
DATE PERFORMED CHAR. CLASSIFICATION TRIALS PARTS APPRAISERS
26-06-08 2 10 2
ICALLY SOUND
Measurement Unit Analysis % Total Variation (
10 AVERAGE Repeatability - Equipment Variation (EV)
2.52 2.506 EV = R x K1 Trials K1 % EV
2.52 2.510 = 0.006 x 4.56 2 4.56
= 0.027 3 3.05
2.52 xa= 2.508 Reproducibility - Appraiser Variation (AV)
0.00 ra= 0.006 AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV
2.52 2.507 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
2.51 2.507 = 0.000

Appraisers 2 3
2.52 xb= 2.507 n = parts r = trials K2 3.65 2.070
0.01 rb= 0.006 Repeatability & Reproducibility (GRR) % GRR
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.027^2 + 0.000^2)}^1/2 2 3.65

= 0.027 3 2.70 Gage system may be acc
xc= Part Variation (PV) 4 2.30
rc= PV = RP x K3 5 2.08 % PV
X= 2.508 = 0.065 x 1.62 6 1.93
2.52 Rp= 0.065 = 0.105 7 1.82
R= 0.006 Total Variation (TV) 8 1.74
xDIFF= 0.001 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.020 = {(0.027^2 + 0.105^2)}^1/2 10 1.62
= 0.109
this limit. Identify the cause and correct. Gage discrimination acce
recalculate R and the limiting value from the This MSA is made after trial even Pre-Pro, including all equipment and critical point that have been determined in PQCS.
ndc standard are ≥ 5
% GRR standard are :
≤ 10% error → the measurement system is acceptable
10% ≤ 30 error → may be acceptable based upon importance of application cost of gage, cost of repair, e
30% ≤ error → measurement system needs improvement, make every effort to identify the problems a
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
APPRAISERS DATE PERFORMED
2 26-06-08
% Total Variation (TV)
= 100 (EV/TV)
= 100(0.027/0.109)
= 25.15
= 100 (AV/TV)
= 100(0.000/0.109)
= 0
= 100 (GRR/TV)
= 100(0.027/0.109)
= 25.148
Gage system may be acceptable
= 100 (PV/TV)
= 100(0.105/0.109)
= 96.79
= 1.41(PV/GRR)
= 1.41(0.105/0.027)
= 5.00
Gage discrimination acceptable
t that have been determined in PQCS.
application cost of gage, cost of repair, etc
ke every effort to identify the problems and
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
2.5 0 0.2 0-300 MM -
2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 2.53 2.51 2.47 2.50 2.49 2.48 2.54 2.52 2.55
2 2.53 2.52 2.48 2.50 2.49 2.49 2.54 2.53 2.54
3
AVE 2.53 2.52 2.48 2.50 2.49 2.49 2.54 2.53 2.55
R 0.00 0.01 0.01 0.00 0.00 0.01 0.00 0.01 0.01
MULYADI 1 2.52 2.50 2.48 2.49 2.49 2.48 2.54 2.53 2.54
2 2.53 2.51 2.47 2.50 2.48 2.49 2.54 2.53 2.54
3
AVE 2.53 2.51 2.48 2.50 2.49 2.49 2.54 2.53 2.54
R 0.01 0.01 0.01 0.01 0.01 0.01 0.00 0.00 0.00
1
2
3
AVE
R
PART
AVERAGE 2.53 2.51 2.48 2.50 2.49 2.49 2.54 2.53 2.54
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
2.5 0-300 MM -
26-06-08 2 10 2
ICALLY SOUND
2.48 2.507 EV = R x K1 Trials K1 % EV
2.49 2.511 = 0.006 x 4.56 2 4.56
= 0.027 3 3.05
2.48 2.505 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
2.48 2.507 = 0.009

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.027^2 + 0.009^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 2.508 = 0.067 x 1.62 6 1.93
2.48 Rp= 0.067 = 0.109 7 1.82
xDIFF= 0.003 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.020 = {(0.029^2 + 0.109^2)}^1/2 10 1.62
= 0.113
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.027/0.113)
= 24.19
= 100 (AV/TV)
= 100(0.009/0.113)
= 8.0306251253
= 100 (GRR/TV)
= 100(0.029/0.113)
= 25.492
= 100 (PV/TV)
= 100(0.109/0.113)
= 96.70
= 1.41(PV/GRR)
= 1.41(0.109/0.029)
= 5.00
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
3.4 0 0.2 0-300 MM -
2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 3.40 3.41 3.39 3.42 3.38 3.43 3.43 3.37 3.44
2 3.40 3.42 3.40 3.42 3.38 3.43 3.44 3.38 3.43
3
AVE 3.40 3.42 3.40 3.42 3.38 3.43 3.44 3.38 3.44
R 0.00 0.01 0.01 0.00 0.00 0.00 0.01 0.01 0.01
MULYADI 1 3.39 3.42 3.40 3.41 3.39 3.42 3.43 3.38 3.44
2 3.40 3.42 3.40 3.42 3.38 3.43 3.44 3.38 3.44
3
AVE 3.40 3.42 3.40 3.42 3.39 3.43 3.44 3.38 3.44
R 0.01 0.00 0.00 0.01 0.01 0.01 0.01 0.00 0.00
1
2
3
AVE
R
PART
AVERAGE 3.40 3.42 3.40 3.42 3.38 3.43 3.44 3.38 3.44
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
3.4 0-300 MM -
26-06-08 2 10 2
ICALLY SOUND
3.44 3.411 EV = R x K1 Trials K1 % EV
3.44 3.414 = 0.005 x 4.56 2 4.56
= 0.025 3 3.05
3.45 3.413 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
3.44 3.415 = 0.000

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.025^2 + 0.000^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 3.413 = 0.065 x 1.62 6 1.93
3.44 Rp= 0.065 = 0.105 7 1.82
xDIFF= 0.002 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.018 = {(0.025^2 + 0.105^2)}^1/2 10 1.62
= 0.108
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.025/0.108)
= 23.17
= 100 (AV/TV)
= 100(0.000/0.108)
= 0
= 100 (GRR/TV)
= 100(0.025/0.108)
= 23.170
= 100 (PV/TV)
= 100(0.105/0.108)
= 97.28
= 1.41(PV/GRR)
= 1.41(0.105/0.025)
= 5.00
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
2.5 0 0.1 0-300 MM -
2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 2.50 2.49 2.52 2.55 2.53 2.51 2.54 2.52 2.47
2 2.50 2.49 2.53 2.54 2.52 2.50 2.53 2.51 2.47
3
AVE 2.50 2.49 2.53 2.55 2.53 2.51 2.54 2.52 2.47
R 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.00
MULYADI 1 2.50 2.50 2.53 2.54 2.52 2.51 2.52 2.52 2.47
2 2.50 2.49 2.53 2.54 2.52 2.52 2.53 2.53 2.48
3
AVE 2.50 2.50 2.53 2.54 2.52 2.52 2.53 2.53 2.48
R 0.00 0.01 0.00 0.00 0.00 0.01 0.01 0.01 0.01
1
2
3
AVE
R
PART
AVERAGE 2.50 2.49 2.53 2.54 2.52 2.51 2.53 2.52 2.47
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
2.5 0-300 MM -
26-06-08 2 10 2
ICALLY SOUND
2.48 2.511 EV = R x K1 Trials K1 % EV
2.49 2.508 = 0.006 x 4.56 2 4.56
= 0.027 3 3.05
2.48 2.509 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
2.48 2.512 = 0.000

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.027^2 + 0.000^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 2.510 = 0.070 x 1.62 6 1.93
2.48 Rp= 0.070 = 0.113 7 1.82
xDIFF= 0.001 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.020 = {(0.027^2 + 0.113^2)}^1/2 10 1.62
= 0.117
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.027/0.117)
= 23.45
= 100 (AV/TV)
= 100(0.000/0.117)
= 0
= 100 (GRR/TV)
= 100(0.027/0.117)
= 23.454
= 100 (PV/TV)
= 100(0.113/0.117)
= 97.21
= 1.41(PV/GRR)
= 1.41(0.113/0.027)
= 5.00
FM-34/ENG-04-08.Rev.00
ATTRIBUTE MSA
NAMA PART : COVER R LOWER NO. LAPORAN :

NO. PART / IDENTITAS : 64460-KWBF-9203 STANDARD/TOLERANSI : TIDAK FLASH
ITEM PENGUKURAN : VISUAL
TANGGAL PENGUKURAN : 26-06-08
HASIL PENGUKURAN
KEPUTUSAN
NO.
PART
MULTIDISC. PENGUKUR 1 PENGUKUR II
TEAM KEPUTUSAN
1 2 1 2
1 OK OK OK OK OK OK
2 NG NG NG NG NG OK
3 NG NG NG NG NG OK
4 OK OK OK OK OK OK
5 NG NG NG NG NG OK
6 NG NG NG NG NG OK
7 OK OK OK OK OK OK
8 NG NG NG NG NG OK
9 OK OK OK OK OK OK
10 OK OK OK OK OK OK
12 NG NG NG NG NG OK
Alat ukur dapat diterima apabila keempat pengujian hasilnya sama
KESIMPULAN : SISTEM PENGUKURAN DAPAT DITERIMA / PERLU DITINGKATKAN*
Catatan:
Diperiksa & Disetujui Dibuat
* coret salah satu
FM-43/ENG-06-08.Rev.00 Tanggal 7 April 2008 Halaman 1 dari 1
GR&R DATA SHEET GR&R DATA SHEET
VARIABLE DATA RESULTS - TOTAL VARIATION VARIABLE DATA RESULTS - TOTAL VARIATION
PART NUMBER / REVISION GAGE NAME APPRAISER A PART NUMBER GAGE NAME APPRAISER A
64470-KWBF-9200 3 DIGITAL CALIPER EKO 64470-KWBF-9203 DIGITAL CALIPER EKO
PART NAME GAGE NUMBER APPRAISER B PART NAME GAGE NUMBER APPRAISER B
COVER L LOWER 1044243 MULYADI COVER L LOWER 1044243 MULYADI
CHARACTERISTIC SPECIFICATION GAGE TYPE APPRAISER C CHARACTERISTIC GAGE TYPE APPRAISER C
2.5 0 0.2 0-300 MM - 2.5 0-300 MM -
CHARACTERISTIC CLASSIFICATION TRIALS PARTS APPRAISERS DATE PERFORMED CHAR. CLASSIFICATION TRIALS PARTS APPRAISERS DATE PERFORMED
2 10 2 26-06-08 2 10 2 26-06-08
APPRAISER/ PART Measurement Unit Analysis % Total Variation (TV)
TRIAL # 1 2 3 4 5 6 7 8 9 10 AVERAGE Repeatability - Equipment Variation (EV)
EKO 1 2.50 2.53 2.51 2.54 2.52 2.49 2.53 2.50 2.47 2.48 2.507 EV = R x K1 Trials K1 % EV = 100 (EV/TV)
2 2.50 2.52 2.50 2.54 2.52 2.49 2.53 2.51 2.48 2.49 2.508 = 0.005 x 4.56 2 4.56 = 100(0.023/0.108)
3 = 0.023 3 3.05 = 21.08
AVE 2.50 2.53 2.51 2.54 2.52 2.49 2.53 2.51 2.48 2.49 xa= 2.508 Reproducibility - Appraiser Variation (AV)
R 0.00 0.01 0.01 0.00 0.00 0.00 0.00 0.01 0.01 0.01 ra= 0.005 AV = {(xDIFF x K2)2 - (EV2/nr)}1/2 % AV = 100 (AV/TV)
MULYADI 1 2.51 2.53 2.51 2.54 2.52 2.49 2.53 2.50 2.48 2.49 2.510 = {(0.00 x 3.65)^2 - (0.02 ^2/(10 x 2))}^1/2 = 100(0.010/0.108)
2 2.50 2.53 2.51 2.55 2.53 2.49 2.52 2.50 2.48 2.50 2.511 = 0.010 = 8.9583904938
3 Appraisers 2 3
AVE 2.51 2.53 2.51 2.55 2.53 2.49 2.53 2.50 2.48 2.50 xb= 2.511 n = parts r = trials K2 3.65 2.070
R 0.01 0.00 0.00 0.01 0.01 0.00 0.01 0.00 0.00 0.01 rb= 0.005 Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/TV)
1 GRR = {(EV2 + AV2)}1/2 Parts K3 = 100(0.025/0.108)
2 = {(0.023^2 + 0.010^2)}^1/2 2 3.65 = 22.902
3 = 0.025 3 2.70 Gage system may be acceptable
AVE xc= Part Variation (PV) 4 2.30
R rc= PV = RP x K 3 5 2.08 % PV = 100 (PV/TV)
PART X= 2.509 = 0.065 x 1.62 6 1.93 = 100(0.105/0.108)

AVERAGE 2.50 2.53 2.51 2.54 2.52 2.49 2.53 2.50 2.48 2.49 Rp= 0.065 = 0.105 7 1.82 = 97.34
(ra + rb + rc) / (# OF APPRAISERS) = R= 0.005 Total Variation (TV) 8 1.74
xDIFF = (Max x - Min x) = xDIFF= 0.003 TV = {(GRR2 + PV2)}1/2 9 1.67 ndc = 1.41(PV/GRR)
* UCLR = R x D4 = UCLR= 0.016 = {(0.025^2 + 0.105^2)}^1/2 10 1.62 = 1.41(0.105/0.025)
= 0.108 = 5.00
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCL R represents the limit of individual R's. Circle those that are beyond this limit. Identify the cause and correct. Gage discrimination acceptable
Repeat these readings using the same appraiser and unit as originally used or discard values and re-average and recalculate R and the limiting value from the This MSA is made after trial even Pre-Pro, including all equipment and critical point that have been determined in PQCS.
NOTES: % GRR standard are :
10% ≤ 30 error → may be acceptable based upon importance of application cost of gage, cost of repair, etc
30% ≤ error → measurement system needs improvement, make every effort to identify the problems and
have them corrected
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
COVER L LOWER 1044243 MULYADI
point 5 Lower Upper 0-300 MM -
2.5 (0~0.2) 2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 2.47 2.50 2.51 2.49 2.53 2.55 2.48 2.54 2.52
2 2.47 2.50 2.50 2.48 2.52 2.54 2.49 2.53 2.52
3
AVE 2.47 2.50 2.51 2.49 2.53 2.55 2.49 2.54 2.52
R 0.00 0.00 0.01 0.01 0.01 0.01 0.01 0.01 0.00
MULYADI 1 2.48 2.49 2.51 2.48 2.52 2.54 2.49 2.53 2.51
2 2.47 2.50 2.51 2.48 2.53 2.54 2.49 2.53 2.52
3
AVE 2.48 2.50 2.51 2.48 2.53 2.54 2.49 2.53 2.52
R 0.01 0.01 0.00 0.00 0.01 0.00 0.00 0.00 0.01
1
2
3
AVE
R
PART
AVERAGE 2.47 2.50 2.51 2.48 2.53 2.54 2.49 2.53 2.52
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
DI COVER L LOWER 1044243 MULYADI
point 5 0-300 MM -
26-06-08 2.5 (0~0.2) 2 10 2
ICALLY SOUND
2.51 2.510 EV = R x K1 Trials K1 % EV
2.50 2.505 = 0.006 x 4.56 2 4.56
= 0.027 3 3.05
2.49 2.504 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
2.50 2.507 = 0.004

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.027^2 + 0.004^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 2.507 = 0.070 x 1.62 6 1.93
2.50 Rp= 0.070 = 0.113 7 1.82
xDIFF= 0.002 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.020 = {(0.028^2 + 0.113^2)}^1/2 10 1.62
= 0.117
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.027/0.117)
= 23.44
= 100 (AV/TV)
= 100(0.004/0.117)
= 3.4120880177
= 100 (GRR/TV)
= 100(0.028/0.117)
= 23.687
= 100 (PV/TV)
= 100(0.113/0.117)
= 97.15
= 1.41(PV/GRR)
= 1.41(0.113/0.028)
= 5.00
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
3.4 (0~0.2) 2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 3.38 3.41 3.43 3.42 3.39 3.40 3.37 3.44 3.41
2 3.38 3.42 3.43 3.42 3.38 3.41 3.38 3.45 3.42
3
AVE 3.38 3.42 3.43 3.42 3.39 3.41 3.38 3.45 3.42
R 0.00 0.01 0.00 0.00 0.01 0.01 0.01 0.01 0.01
MULYADI 1 3.39 3.42 3.42 3.41 3.38 3.42 3.37 3.44 3.41
2 3.38 3.42 3.43 3.42 3.38 3.41 3.37 3.44 3.41
3
AVE 3.39 3.42 3.43 3.42 3.38 3.42 3.37 3.44 3.41
R 0.01 0.00 0.01 0.01 0.00 0.01 0.00 0.00 0.00
1
2
3
AVE
R
PART
AVERAGE 3.38 3.42 3.43 3.42 3.38 3.41 3.37 3.44 3.41
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
DI COVER LOWER 1044243 MULYADI
point 8 0-300 MM -
26-06-08 3.4 (0~0.2) 2 10 2
ICALLY SOUND
3.43 3.408 EV = R x K1 Trials K1 % EV
3.43 3.412 = 0.005 x 4.56 2 4.56
= 0.025 3 3.05
3.43 3.409 = {(0.00 x 3.65)^2 - (0.03 ^2/(10 x 2))}^1/2
3.44 3.410 = 0.000

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.025^2 + 0.000^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 3.410 = 0.070 x 1.62 6 1.93
3.43 Rp= 0.070 = 0.113 7 1.82
xDIFF= 0.001 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.018 = {(0.025^2 + 0.113^2)}^1/2 10 1.62
= 0.116
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.025/0.116)
= 21.59
= 100 (AV/TV)
= 100(0.000/0.116)
= 0
= 100 (GRR/TV)
= 100(0.025/0.116)
= 21.595
= 100 (PV/TV)
= 100(0.113/0.116)
= 97.64
= 1.41(PV/GRR)
= 1.41(0.113/0.025)
= 6.00
FM-34/ENG-04-08.Rev.00
GR&R DATA SHEET
2.5 (0~0.1) 2 10 2
APPRAISER/ PART
TRIAL # 1 2 3 4 5 6 7 8 9
EKO 1 2.55 2.52 2.50 2.49 2.54 2.51 2.50 2.53 2.48
2 2.54 2.53 2.50 2.48 2.53 2.51 2.50 2.53 2.49
3
AVE 2.55 2.53 2.50 2.49 2.54 2.51 2.50 2.53 2.49
R 0.01 0.01 0.00 0.01 0.01 0.00 0.00 0.00 0.01
MULYADI 1 2.54 2.52 2.51 2.50 2.54 2.51 2.50 2.54 2.48
2 2.54 2.52 2.51 2.49 2.54 2.52 2.50 2.53 2.48
3
AVE 2.54 2.52 2.51 2.50 2.54 2.52 2.50 2.54 2.48
R 0.00 0.00 0.00 0.01 0.00 0.01 0.00 0.01 0.00
1
2
3
AVE
R
PART
AVERAGE 2.54 2.52 2.51 2.49 2.54 2.51 2.50 2.53 2.48
* UCLR = R x D4 =
NOTES:
GR&R DATA SHEET
DI COVER L LOWER 1044243 MULYADI
point 11 0-300 MM -
26-06-08 2.5 (0~0.1) 2 10 2
ICALLY SOUND
2.51 2.513 EV = R x K1 Trials K1 % EV
2.50 2.511 = 0.005 x 4.56 2 4.56
= 0.023 3 3.05
2.49 2.513 = {(0.00 x 3.65)^2 - (0.02 ^2/(10 x 2))}^1/2
2.50 2.513 = 0.000

Appraisers 2 3
GRR = {(EV + AV )}
2 2 1/2
Parts K3
= {(0.023^2 + 0.000^2)}^1/2 2 3.65

rc= PV = RP x K3 5 2.08 % PV
X= 2.513 = 0.060 x 1.62 6 1.93
2.50 Rp= 0.060 = 0.097 7 1.82
xDIFF= 0.001 TV = {(GRR + PV )} 2 2 1/2
9 1.67 ndc
UCLR= 0.016 = {(0.023^2 + 0.097^2)}^1/2 10 1.62
= 0.100
have them corrected
SHEET
TAL VARIATION
APPRAISER A
EKO
APPRAISER B
MULYADI
APPRAISER C
-
2 26-06-08
= 100 (EV/TV)
= 100(0.023/0.100)
= 22.84
= 100 (AV/TV)
= 100(0.000/0.100)
= 0
= 100 (GRR/TV)
= 100(0.023/0.100)
= 22.837
= 100 (PV/TV)
= 100(0.097/0.100)
= 97.36
= 1.41(PV/GRR)
= 1.41(0.097/0.023)
= 6.00
FM-34/ENG-04-08.Rev.00
ATTRIBUTE MSA
NAMA PART : COVER L LOWER NO. LAPORAN :

NO. PART / IDENTITAS : 64470-KWBF-9203 STANDARD/TOLERANSI : TIDAK FLASH
ITEM PENGUKURAN : VISUAL
TANGGAL PENGUKURAN : 26-06-08
HASIL PENGUKURAN
KEPUTUSAN
NO.
PART
MULTIDISC. PENGUKUR 1 PENGUKUR II
TEAM KEPUTUSAN
1 2 1 2
1 OK OK OK OK OK OK
2 OK OK OK OK OK OK
3 NG NG NG NG NG OK
4 OK OK OK OK OK OK
5 NG NG NG NG NG OK
6 NG NG NG NG NG OK
7 OK OK OK OK OK OK
8 NG NG NG NG NG OK
9 OK OK OK OK OK OK
Alat ukur dapat diterima apabila keempat pengujian hasilnya sama
KESIMPULAN : SISTEM PENGUKURAN DAPAT DITERIMA / PERLU DITINGKATKAN*
Catatan:
Diperiksa & Disetujui Dibuat
* coret salah satu
FM-39/ENG-04-08.Rev.00 Tanggal 7 April 2008 Halaman 1 dari 1
KWB HS HA HB Q NF
Part Name COVER R/L LOWER PROSE
No Rev : 00 Dokumen ini adalah dokumen kualitas yan
Part No 64460/70-KWBF-9203
PENGENDALIAN KARAKTERISTIK KUALITAS (PRODUK)

NAMA PROSES
CODE KUALITAS PRODUK KONTROL OPERASION
[Disertai Ilustrasi Produk in Proses]
F f
NO PARAMETER STANDARD Methode Frekuensi
1 RECEIVING
a. Resin 1 Jenis Material ABS 10 JK2A Label Per Lot
2 Jumlah Surat Jalan Hitung
3 Kemasan Tertutup Visual
b. Master Batch 1 Jenis Master Batch JB 1112-30 Grey Label Per Lot
3 Kemasan Tertutup Visual
2 INCOMING INSPECTION
a. Resin C - 1 Warna Sampel Material Banding Per Lot
A A 2 Kondisi Fisik Tdk Basah / Kotor Visual
4 Berat 25 Kg / Zak Timbang
5 COA ABS 10 JK2A Visual Cek Dokumen
b. Master Batch C - 1 Warna Sampel Material Banding Per Lot
A A 2 Kondisi Fisik Tdk Basah / Kotor Visual
4 Berat 25 Kg / Zak Timbang
5 COA JB 1112-30 Grey Visual Cek Dokumen
3 STORAGE (Ware House) 1 Cara Penanganan Ditumpuk 20 Shap/Pallet Rutin

2 Cara Perawatan Terlindung Ditutup
3 Lama Penyimpanan Max. 3 bln Label
4 Sistem Pengeluaran FIFO Label
4 PREPARE / MIXING MATERIAL 1 Jenis Material ABS 10 JK2A (Original) Label Rutin
2 Jenis Master Batch JB 1112-30 Grey Label
3 Komposisi 1% Timbang
Master Batch
5 INJECTION MOLDING PROCESS 1 Warna Grey Banding Per Pcs

C C 2 Visual Tidak Flash Finishing
(Master Sample)
- C 3 Marking Part Tanggal, Shift & Initial Tulis
4 Packing Container Box 7008 Hitung & Label 20 Pcs
6 QUALITY INSPECTION 1 Warna Grey Banding Per Jam
C C 2 Visual Tidak Flash N=1
(Master Sample)
PT. Yasunli Abadi Utama Plastic
No Dok : 01-ENG-YAUP/P.QC.S-KWB-AHM KWB HS HA HB Q NF
No Rev : 00
Part Name COVER R/L LOWER PROSE
No Rev : 00 Dokumen ini adalah dokumen kualitas yan
Part No 64460/70-KWBF-9203
PENGENDALIAN KARAKTERISTIK KUALITAS (PRODUK)

NAMA PROSES
CODE KUALITAS PRODUK KONTROL OPERASION
[Disertai Ilustrasi Produk in Proses]
F f
NO PARAMETER STANDARD Methode Frekuensi
3 Berat Product Spec Timbang Per Jam
4 Material ABS 10 JK2A Visual (Label N = 1
E A 5 Visual Painting Painting Test Painting
D C 6 Dimensi Drawing Spec Caliper
a. Point 2 PIS Tebal : 2.5 (0 ~ 0.2) Caliper
b. Point 3 PIS Lubang : Ø8 (0 ~ 0.2) Caliper
c. Point 5 PIS Tebal : 2.5 (0 ~ 0.2) Caliper
d. Point 6 PIS Lubang : Ø8 (0 ~ 0.2) Caliper
e. Point 7 PIS Slot : 11x13 (0 ~ 0.2) Caliper
f. Point 8 PIS Tebal : 3.4 (0 ~ 0.2) Caliper
g. Point 10 PIS Lubang : Ø8 (-0.2 ~ 0) Caliper
h. Point 11 PIS Tebal : 2.5 (0 ~ 0.1) Caliper
i. Point 13 PIS Slot : 10x12 (0 ~ 0.2) Caliper
j. Point 14 PIS Tebal Rata2 : 2.3+0.1 Caliper
7 STORAGE (Ware House) C C 1 Cara Penanganan Ditumpuk 20 Box/Pallet Rutin
(5 Shap)
2 Cara Perawatan Terlindung Ditutup
3 Lama Penyimpanan Max. 2 Bulan Label
4 Sistem Pengeluaran FIFO Label
8 OUT GOING INSPECTION 1 Warna Grey Banding Per Deliv

C C 2 Visual Tidak Flash N=5
(Master Sample)
3 Material ABS 10 JK2A Visual (Label Zak)
E A 4 Visual Painting Painting Test Painting
D C 5 Dimensi Drawing Spec Caliper
a. Point 2 PIS Tebal : 2.5 (0 ~ 0.2) Caliper
b. Point 3 PIS Lubang : Ø18 (0 ~ 0.2) Caliper
c. Point 5 PIS Tebal : 2.5 (0 ~ 0.2) Caliper
d. Point 6 PIS Lubang : Ø18 (0 ~ 0.2) Caliper
e. Point 7 PIS Slot : 11x13 (0 ~ 0.2) Caliper
f. Point 8 PIS Tebal : 3.4 (0 ~ 0.2) Caliper
g. Point 10 PIS Lubang : Ø8 (-0.2 ~ 0) Caliper
h. Point 11 PIS Tebal : 2.5 (0 ~ 0.1) Caliper
i. Point 13 PIS Slot : 10x12 (0 ~ 0.2) Caliper
j. Point 14 PIS Tebal Rata2 : 2.3+0.1 Caliper
9 DELIVERY TO AHM 1 Nama Produk Surat Jalan Label Per Lot
2 Jumlah Hitung
FM-24b/ENG 12-05 Rev.01
POINT QUALITY KRITIS - Diberi tanda :
INTENSITAS KEJADIAN (f) : A=Pernah KEJADIAN, B=Prediksi KEJADIAN, C=Monitoring Status
FAILURE MODE (F) : Diisi sesuai dengan TABEL JENIS KEGAGALAN yang telah terdefinisikan
PREPARED BY :
PT. YASUNLI AUP
PROSES QC SHEET Approved Checked
Dokumen ini adalah dokumen kualitas yang akan dijadikan referensi AUDIT maupun VERIFIKASI KUALITAS
Sukiran Heri S.
RISTIK KUALITAS (PRODUK) PENGENDALIAN PRODUKSI MANUFAKTUR
KONTROL OPERASIONAL KONDISI NORMAL KONTROL OPERASIONAL

Waktu Evaluasi Identifikasi ALAT dan
Check Sheet Penanggung Jawab NO STANDARD Methoda Frekuensi
Inspeksi DATA Kontrol Parameter
Buka Zak FM-01/GDM- Mat'l WH Operator 1 Bln

08.06 (03)
Buka Zak Mat'l WH Operator 1 Bln
Buka Zak FM-11/QC- IQC 1 Bln 1 Warna IK-QA-01 Visual Per Lot
12-05 (02) (04)
FM-06B/QA-
12-05 (02)
Cek Dokumen
Buka Zak IQC 1 Bln 2 Berat IK-GDM.01 Manual Per Lot
(01)
a Timbangan Duduk 310 Kg
- Verifikasi IK/ENG-06 Internal 6 Bulan
Cek Dokumen - Kalibrasi PS-11 Eksternal 1 Tahun
Harian FM-03/GDM- Mat'l WH Operator - 1 Lay Out IK-GDM.02 Manual Per Lot
04.07 (00) - (02)
FM-04/GDM- 1 Bln
12.05 (02) 1 Bln
Harian FM-35/Inject CP Operator 1 Bln 1 Komposisi IK/PW-001 Digital Per Part
09.07 (01) (04)
a Timbangan Digital 0 - 10000 Digital
- Kalibrasi PS-11 Eksternal 1 Tahun
2 Pengisian Bahan IK/PW-001 Manual Per Jam

(04)
Mass Prod FM-08/Inject- Injection Operator 1 Bln 1 Setting Mesin IK-TECH-02 Manual Per Part
12-05 (04) (MC = 850~1050) (04) 1 1
a. Temp. Heater 200 ~ 240
b. Temp. Material 200 ~ 240
c. Cooling Core 18
Cooling Cavity 25
d. Temp. Core 30 ~ 50
Temp. Cavity 40 ~ 50
e. Temp. Hopper 70 ~ 90
2 Proses Produksi IK-04.02
3 Standard Packing IK/ENG-02 Manual Per Box

Mass Prod FM-08/Inject- Prod QC 1 Bln 1 Hasil Produksi IK-4.02-QC- Manual Per Part
12-05 (04) 001 (07)
PREPARED BY :
PT. YASUNLI AUP
PROSES QC SHEET Approved Checked
Dokumen ini adalah dokumen kualitas yang akan dijadikan referensi AUDIT maupun VERIFIKASI KUALITAS
Sukiran Heri S.
RISTIK KUALITAS (PRODUK) PENGENDALIAN PRODUKSI MANUFAKTUR
KONTROL OPERASIONAL KONDISI NORMAL KONTROL OPERASIONAL

Waktu Evaluasi Identifikasi ALAT dan
Check Sheet Penanggung Jawab NO STANDARD Methoda Frekuensi
Inspeksi DATA Kontrol Parameter
Mass Prod FM-08/Inject- Prod QC 1 Bln 2 Dimensi IK-QA-01 Digital 1 Pc / Jam
12-05 (04) (04)
FM25/QA- a Caliper 0 - 300 Digital
12-05 (02) i - Verifikasi IK/ENG-06 Internal 6 Bulan
3 Berat IK-QA-01 Digital 1 Pc / Jam

(04)
a Timbangan Digital 0 - 6100 Digital
Harian FM-01/Inject- Ready WH Operator - 1 Penerimaan IK-GDR-01 Manual Per Shift

12-05 (01) (02) 1
FM-01/GDR- - 2 Penyimpanan
12-05 (01) 1 Bln
FM-03/GDR- 1 Bln 3 Pengeluaran IK-GDR-02
12-05 (02) (02)
Mass Prod FM25/QA- OQC 1 Bln 1 Dimensi IK-QA-01 Digital 5 Pcs / Deliver
12-05 (02) (04)
a Caliper 0 - 300 Digital
Persiapan FM-4/Delivery- Delivery Operator 1 Bln 1 Schedule IK/Delivery/01 Manual Per Part
Delivery 12-05 (01) (00)
TABEL dan DEFINISI FAILURE MODE (F) : Code FAILURE MODE CHARACTERISTICS :
A Kerusakan Fisik : Zak / Kaleng Sobek / Bocor, Basah
B Kerusakan : Fitting Seret, Part Assy Cacat
C Produksi Cacat : Sink Mark, Short Mat'l, Flash, Dan Lainnya
Prediksi KEJADIAN, C=Monitoring Status D Dimensi Out Spec
S KEGAGALAN yang telah terdefinisikan E Painting Cacat : Blobor, Scratch, Kotor, Warna Tidak Standar, Dan Cacat Painting Lainnya
F Printing Cacat : Blobor, Kotor, Warna Tidak Standar, Dan Cacat Printing Lainnya
G Part Assy Tidak Lengkap, Lepas
H Profil Part : Melengkung (Bending), Menciut, Dan Cacat Profil Lainnya
I Part Assy Terdapat Celah / GAP
J Hasil Uji : Produksi Pecah, Retak, Dan Lainnya
PREPARED BY :
T. YASUNLI AUP PAGE

Prepared
2/3
Maman K.
MANUFAKTUR
KONTROL OPERASIONAL
Penanggung
Check Sheet
Jawab
FM-11/QC- IQC
12-05 (02)
FM-06B/QA-
12-05 (02)
FM-01/GDM- IQC
08.06 (03)
FM-15/ENG Engineering
FM-26/ENG-
08-07 (04)
FM-03/GDM- Mat'l WH
04.07 (00)
FM-04/GDM-
12.05 (02)
FM-35/Inject CP Operator
09.07 (01)
FM-26/ENG-
08-07(04)
FM-23/Inject CP Operator
12.05 (02)
FM-15/Inject- Technisi
12-05 (03)
FM-08/Inject- Injection
12-05 (04) Operator
Eng-Std.Pack Engineering
FM-08/Inject- Prod QC
12-05 (04)
PREPARED BY :
3/3
T. YASUNLI AUP PAGE
Prepared
3/3
Maman K.
MANUFAKTUR
KONTROL OPERASIONAL
Penanggung
Check Sheet
Jawab
FM25/QA- Prod QC
12-05 (02)
FM-26/ENG-
08-07(04)
FM25/QA- Prod QC
12-05 (02)
FM-26/ENG-
08-07(04)
FM-01/Inject- Ready WH
12-05 (01)
FM-01/GDR-
12-05 (01)
FM-03/GDR-
12-05 (02)
FM25/QA- OQC
12-05 (02)
FM-26/ENG-
08-07(04)
FM-4/Delivery- Delivery
12-05 (01) Operator
h
Lainnya
Standar, Dan Cacat Painting Lainnya

Dan Cacat Printing Lainnya
acat Profil Lainnya

PT. Yasunli Abadi Utama Plastic
APPROVAL SHEET
Customer : PT. Astra Honda Motor Date :
Part Name : Cover R/L Lower No.Dok. : AS-AHM-KWB-01
Part Code : 64460/70-KWBF-9203 Revisi : 00
Model : KWB
Weight Part : R = 308.4 & L = 293.6 Gr / Pc Totals : 632.3
Weight Runner : 30.3 Gr Cavity : 2 (Family Mould Cycle Time : 65
Remarks:
CHECK POINT:
A. Part hasil INJECTION tidak boleh :
1. Flash 7. Weld line
2. Short material 8. White Mark
3. Belang 9. Baret / Scratch
4. Sink mark 10. Gelembung Udara
5. Silver 11. Kasar
6. Over cut 12. Dan yang lainnya yang disebabkan
oleh proses INJECTION.
B. Potongan gate harus rata & rapi.
C. Warna material harus sesuai dengan standard.
D. Appearance part mengacu pada limit sample (sample approval).
E. Part hasil painting : tidak nyerep dan cacat painting lainnya.
Material Secondary Process

Kind : ABS Techno Spray :-
Grade : 10JK2A Printing :-
Colour : Natural / Grey Hotstamp :-
FM-11/ENG - 12 - 05. Rev.02

Prepared by Checked by Approved by
Maman K. Heri S. Sukiran

Gr
Cycle Time : 65
NF
N
F
ya yang disebabkan
s
Approved by
Sukiran
CHECKING AID VERIFICATION FORM
Part Certification Date Verified:
SECTION I MANUFACTURING LOCATION
Make department Verified by Title Telephone #
Part Number Part Description
Drawing Number ECL ECL Date
Applicable Spec Applicable Spec date
SECTION III CHECKING AID REQUIREMENTS

1.- Check the content of the control plan to find the applicable part specific checking aids such as holders,
fixtures etc. that are to be used to hold the part while measuring this part number, including the QC
specifications if applicable. (THIS DOES NOT INCLUDE GAGES).
2.- List by number or description the checking aids required to be used for inspection purposes.
3.- Checking aids are to be verified that they work, are free from damage, that the last verification date has not
expired and that they have been accepted and marked as good during the last verification.
Not Damaged
Not Expired
Functional
ITEM # Checking Aid Checking aid Number NOTES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
NOTES / COMMENTS NOTES

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PPAP HEADER INFORMATION FORM PART FAMILY

COVER R/L MAIN PIPE

CUSTOMER PART NUMBER: 64460/70-KWBF-9203

CUSTOMER REV. LEVEL: NF REV DATE: 11 Januari 2008

SUPPLIER NAME: PT. YASUNLI AUP.

CUSTOMER NAME: PT. Astra Honda Motor

LAST MODIFIED BY: EKO W.P. DATE: 28 Juli 2008

Item Report Document

Reviewed & Approved

II MANUFACTURING PROCESS DESIGN OUTPUT

III FINAL REVIEW

5 Error Proofing Method C - Close

06/SM/Eng-Y1/KWBF/AHM & DE/Eng-

10 Methods of Rapid Detection & Feedback of - -

Reviewed by: Reviewed by:

Part Number Part Name Engineering Drawing Change Level

Drawing Change Level

COVER R/L LOWER PROSES Q

DIAGRAM FLOW PROSES

Storage (WH) Storage (WH) Storage (WH)

Prepare Mixing Mixing

Injection Moulding Injection Moulding Injection Moulding

Quality Quality Quality

Storage Storage Storage

Out Going Out Going Out Going

FM-24a/ENG 12-05 Rev.01

IDENTIFIKASI INPUT PROSES

CATATAN PENGENDALIAN DOKUMEN

PT. ASTRA HONDA MOTOR PAGE

NAMA MAKER / VENDOR

Co., Ltd. (PT. Sojitz)

YEAR : 2008 FMEA DATE : 11-03-2008 REV : 00

Process Function / Potential Causes Responsibility & Target Action Result

Jenis material salah - Salah label material 1 (D) pengecekan visual 7 7

Jenis masterbatch salah - Salah label masterbatch 1 (D) pengecekan visual 7 7

- Berat tidak sesuai (D) pengecekan visual

colormetric - Hanya pengecekan visual (P) Instruksi Kerja

1 (Penumpukan Terlalu 1 Penyimpanan Material 7 7

Tinggi) (Standard Penumpukan)

YEAR : 2008 FMEA DATE : 11-03-2008 REV : 00

Process Function / Potential Causes Responsibility & Target Action Result

Material Lain Standard (Appearance) Berbagai Material 1 Penyediaan Material 7 7

- Komposisi Material & - Produk Tidak Sesuai - Komposisi MB Tidak - Timbangan

Lubang Screw Over Assy Unit Motor 1

pada area locking - Lubang flash 6 (P) Standard Setting 7 42

YEAR : 2008 FMEA DATE : 11-03-2008 REV : 00

Process Function / Potential Causes Responsibility & Target Action Result

ok produk antara kanan

O (Occurance) = Menentukan tingkat kejadian / seberapa sering penyebap kegagalan tsb

D (Detection) = Kemampuan sistem kontrol design dalam mendeteksi penyebap kegagalan

RPN ≥1/2 dari yang terbesar harus diperbaiki

Dimention Result Rev. : 00 / 07 - 04 - 2008

Logo Perusahaan Page : 1 of 1

Company : Part Number (Company) : Part Number (Customer) :

Item Dimension/ Spesification Tol. Measurement Results Ok

Material Test Result Rev. : 00 / 07 - 04 - 2008

Logo Perusahaan Page : 1 of 1

Supplier Part Name

Cover R/L Lower

Name of Laboratory Part Number

2.51 2.507 = 0.000

= {(0.027^2 + 0.000^2)}^1/2 2 3.65

% Total Variation (TV)

2.48 2.507 = 0.009