18- POINT PPAP PLAN AND APPROVAL AND WAIVER PPAP SUBMISSION LEVELS 1 2 3 4 5

CUSTOMER/SUPPLIER CFUSA-NOVI/SUPPLIERS NAME PART NAME: ENGINEERING CHANGE LEVEL (ECN): EXPECET PPAP SUBMISSION DATE:: PART NUMBER: REASON FOR SUBMISSION: START OF PRODUCTION:

1.

DESIGN RECORDS

A) B) C)

CURRENT LEVE BLUEPRINT CFUSA ENGINEERING SPECS (APPL. ONLY) OTHER RELEVENT SPECS (APPL ONLY)

WHAT TO LOOK FOR: A) B) DOCUMENTS AND SPECS AVAILABLE AND ATT HE LATEST LEVELS; ITEMIZED LIST OF DOCUMENTS AND REV LEVELS

2.

ENGINEERING CHANGE DOCUMENTS

ANY OUTSTANDING ECS INCLUDED ON PART NOT INCLUDED IN CURRENTLEVEL PRINT(S) WHAT TO LOOK FOR: A) B) ENGINEERING CHANGE AVAILABLE AND LISTED; PENDING CHANGES THAT MAY AFFEST SUBMISSION

3.

CUSTOMER ENGINEERING APPROVAL

DEVIATION REQUESTS- APPROVED WHAT TO LOOK FOR: A) B) C) D) COPIES OF APPROVED DEVIATIONS; COPIES OF SUBMITTED DEVIATIONS AWATIING APPROVAL COPIES OF APPROVAL OF SREA ALIGNMENT WITH THE REST OF DOCS(FMEA,CP, ETC)

4.

DESIGN FMEA

INCLUDE (FOR DFEMA SUPPLIER ONLY) WHAT TO LOOK FOR: A) AT LEAST LATEST LEVEL

5.

PROCESS FLOW DIAGRAMS

INCLUDE
WHAT TO LOOK FOR: A) LATEST LEVEL B) ALIGNMENT WITH THE REST OF THE DOCUMENTS (CP,PFMEA, ETC.) C) INLCUDE OUTSIDE PROCESSES

D) E)

ALL OPERATIONS INCLUDED (INCOMING TO SHIPPING) DUNNAGE, REWORK AREAD, INSPECTION AREAS, STORAGE ETC INCLUDED

18- POINT PPAP PLAN AND APPROVAL AND WAIVER PPAP SUBMISSION LEVELS 1 2 3 4 5 6. PROCESS FMEA
INCLUDE
WHAT TO LOOK FOR: A) ACTIONS WITH RESPONSIBILITIES AND DATES B) IF SEVERITY RANKED 9 OR 10 WITH ACTIONS IN PLCE AND TOP 3 OVERALL RPNS C) SEVERITY AND DETECTION ACCORDING TO THE TABLE OF AIAG D) FAILURE MODES FOR ALL EQUAL PROCESSES, ALL CRITICAL CHARACTORISTICS AND USAGE OF POKE-YOKES. E) ALL OPERATIONS FORM INCOMING TO SHIPPING

7.

CONTROL PLAN

INCLUDE (INCOMING TO SHIPPING)

WHAT TO LOOK FOR:

A)

B) C)

ROBUST AND REAL ACTION PLAN TO PROTECT CFUSA, SPC TOLERANCES, SPECS, LINKS TO STANDARDS, AND INSPECTION FREQUENCIES ARE APPROPRIATE CONTROLS ALIGNED WITH PFMEA ALL OPERATIONS INLCUDED FROM INC9OMING TO SHIPPING

8.

MEASUREMENT SYSTEMS ANALYSIS (MSA)

INLCUDE MSAS FOR ALL EQUIPMENT/MEASURING DEVICES, TESTERS UTILIZED IN IDENTIFYING ACCEPTABILITY of product, and also for the critical characteristics: MAX 30%
WHAT TO LOOK FOR:

R&R for testers, gages and equipment to measure critical characteristics. Reaction plan for R&R btwn 20%-30%. MSA complete, measurement specs match control plan; Bias, linearity, stability and gag R&R

9.

DIMENTIONAL RESULTS

100% LAYOUT TO CURRENT LEVEL PRINT/MARK BOLD ON DIM REPORT WHAT TO LOOK FOR:

ALL CHARACERISTICS OF THE PRINT, ALL CHARATERISTICS WITH IN SPEC, BALLOONED PRINT SHOWING NUMBER ASSIGNED ON DIM REPORT, NUMBER OF PARTS USED IN DIM REPORT, DIM REPORT BY EACH CAVITY/MOLD.

10

MATERIAL PERFORMANCE TEST RESULTS

100% CONFORMANCETO ALL MATERIAL AND PERFORMANCE TESTING WHAT TO LOOK FOR:

A) DOCUMENTATION OF THE HEAT TREAT SOURCE B) LAB CERTS WITH CERTIFICATIONS C) METALLURGICAL AND COMPOSITION REPORTS IF APPLICABLE D) PERFORMANCE REPORT DATA-IF NOT REQUIRED NOTIFICATION NEEDED BY ENGINEER REPRESENTATIVE.

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INITIAL PROCESS STUDIES

INCLUDE IPSS SHOWING COMPLIANCE TO CAPABILITY >/= 1.67 WHAT TO LOOK FOR:

30 PC USED FOR STUDY PER CAVITY/MOLD/WORK FIXTURE STATISTICAL METHODSHOULD BE CLEAN FUEL USA APPROVED

12

QUALIFIED LABORATORY DOCUMENTS

INCLUDE DOCUMENTS SHOWING QUALIFIED LAB CERTIFICATIONS FOR ALL DIMENTIONAL/PERFORMANCE TESTING WHAT TO LOOK FOR: CURRENT CERRTIFICATIONS, SUPPLIERS CERTTIFICATIONS AND SUPPLIER OR EXTERNAL SUPPLIER MUST BE ISO/IEC 17025 CERTIFIED

18- POINT PPAP PLAN AND APPROVAL AND WAIVER PPAP SUBMISSION LEVELS 1 2 3 4 5

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Appearance Approval Report

THIS AAR WOUDLBE REQURED IF THERE WAS AN APPEARANCE CHANGE AND ONLY IF APPLICABLE AND NECESSARY BY CFUSA. WHAT TO LOOK FOR: A) Customer Standards B) Report Approved

14

Sample Product

UP TO 30 PIECES PER CFUSA EXPECTATIONS WHAT TO LOOK FOR: A) PACKAGING B) PIECE RUN AT PERMANENT MFG. LINE C) IDENTIFY AS PPAP SAMPLES AND NUMBERED TO CORRELATE THE DIMENTIONAL REPORT TO BE RETAINED AT SUPPLIER LOCATION WHAT TO LOOK FOR: A) DURING APQP CFUSA ESTABLISH IS REQ AND TIMING B) WELL IDENTIFIED W./ MFG DATE,DIM REPORT,CAVITY, ETC C) KEPT IN A SAFE PLACE AND AVAILABLE UPON REQUEST

15

MASTER SAMPLES

16

CHECKING AIDS

INCLUDE SUPPORTING DOCUMENTATION FOR ANY PRODUCT-UNIQUE CHECKING AIDS (PRINTS, EC LEVEL, ID, ETC.) WHAT TO LOOK FOR: WHAT MASTERS ARE USED TO ENSURE THE GAGE IS BEING GIVEN CONFIDENT RESULTS, ID ON EACH, CONTROLLED AND MAINTAINED AND THE FREQUENCY OF MATERING THOSE GAGES.

17

RECORDS OF COMPLIANCE WITH CUSTOMER SPECIFIC REQUIREMENTS

EVIDENCE OF IMDS SUBMISSION/ACCEPTANCE Include a) packaging instruction, b) CFUSA equipment/tooling property master list, c) preventative maintenance plan. WHAT TO LOOK FOR: A) IMDS DOCUMENTS B) PACKAGING INSTRUCTIONS C) EQUIPMENT, TOOLING, PATTERNS MASTER LIST D) PREVENTATIVE MAINTENCE LIST E) CRITICAL CHARACTERISTICS LIST F) PPAPS (SUBMITTED IN ENGLISH) G) ALL OTHER DATA/ INFO DEEMED BY CFUSA

18

PARTS SUBMISSION WARRANT (PSW)

INCLUDE COMPLETE PSW TO CFUSA TO BE APPROVED AND SIGNED OFF WHAT TO LOOK FOR: A) SLL FIELDS FILLED IN ACCURATELY B) COMMENTS FILLED AND COMPREHENSIBLE C) REVISION LEVELS TO MARCH THE DRAWINGS (MIN ECN NUMBER) D) USAGE OF THE FORMAT AIAG EDITION

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S U P P LIE R A P P R O VA L O F P P A P P LA N Q U A LITY M A N A G E R / Q U A LITY E N G IN E E R

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C F USA Q UA LITY A PPR O VA L O F PPA P PLA N SUPPLIER Q UA LITY ENGINEER

18- POINT PPAP PLAN AND APPROVAL AND WAIVER PPAP SUBMISSION LEVELS 1 2 3 4 5 CFUSA PPAP PREPARATION CHECKLIST

PURPOSE: THE PURPOSE OF THE WORKBOOK IS TO PROVIDE A TOOL FOR THE SUPPLIER TO COMPARE THE CONTENT OF THEIR PPAP TO THE EXPECATIONS OF CFUSA FOR THE PART. SCOPE: LIST THE TECHNICAL DOCUMENTS RELATED TO THE PART; ENGINEERING DRAWINGS, SPECS, ETC. COMMUNICATE THE GENERAL CFUSA EXPECTATIONS FOR THE PPAP COMPLETION. THIS DOCUMENT DOES NOT SUPERCEDE ANY ENGINEERING DOCUMENT OR SPECIFICATION, NOR DOES IT TAKE PRECEDENCE OVER THE ACTUAL PPAP SUBMISSION IN ANYWAY, SHAPE OR FORM. THIS WILL BE BOUNCED OFF OF THE ACTUAL PPAP AND EXPECTED TO BE SUBMITTED WITH THE PPAP AS WELL AS THE PPAP CHECKLIST. INSTRUCTIONS: A) ENSURE TO CIRCLE THE PPAP SUBMISSION LEVEL YOURE SUBMITTING IS CIRCLED AND THIS IS REPEATED ON EACH PAGE OF THE PLAN. B) IN THE FIRST BOX, ENSURE THE CUSTOMER AND PART INFORMATION IS CORRECT AND PART NUMBER AND DESCRITION ARE ACCORDING TO ALL DOCUMENTS. DO NOT LEAVE ANY BLANK AREAS OR THE PPAP PACKAGE WILL BE DECLINED. C) YOUR PPAP SUBMISSION ITEMS WILL BE ADDED ACCORDING TO THE 18-POINTS IN THE FIRST COLUMN AND THEIR DESCRIPTION AND EXPECTATIONS IN THE SECOND COLUMN. D) ONCE THE 18 ITEMS HAVE BEEN REVIEWED, UNDERSTOOD AND ADDED TO THE PACKAGE ABND YOU ARE CONFIDENT IT IS READY TO BE SUBMITTED YOU MAY PROCEED TO STEP E AND SIGN OFF. E) SIGN THE SECTION REQUESTING SUPPLIER APPROVAL OF PPAP PLAN AND DATE IT.

IF YOU FULLY UNDERSTAND THESE DIRECTIONS, YOUR PPAP PACKAGE IS READY TO SUBMIT PLEASE SIGN BELOW.

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APPROVAL & WAIVER SUBMITTER QUALITY MANAGER/QUALITY ENGINEER/SQE