The document discusses integrating key PPAP elements into a single Excel tab rather than across multiple tabs. It outlines five unique PPAP elements and steps to plot each element on a single chart, including plotting the customer specification, gage R&R estimate, measurements from initial samples, and capability study statistics from each cavity. The integrated approach puts all necessary information on one chart that is navigable via an Excel slider bar to compare different traits, improving upon traditional multi-tabbed workbooks.

1. Integrating the PPAP Elements

2. Most PPAP Workbooks Are
Multi-Tabbed Excel Files Which …

3. … Force Users to Jump Between
Many Tabs to Compare Key Elements
±

4. A Better System Would Integrate
All Key Elements Into a Single Tab

5. Element #1:
Everything starts
with the customer
specification; it
establishes the
baseline against
which the process
is compared

6. Element #2:
Specifications with
variable data
require gage R&R
studies to estimate
percent of toler-
ance occupied by
gaging error.

7. Element #3:
Measurements
from T1 samples
provide an initial
insight into a new
part’s evolution
from concept to
production.

8. Element #4:
All processes have
variability. A cap
study is designed
to measure this
variability and
compare it to the
customer spec.

9. Element #5:
Customers require
cap studies for
every cavity. This
is another aspect
of a PPAP that
engineers need to
evaluate & judge.

10. Reminder: Our Objective is to
Integrate These 5 Unique Elements
❶❷❸❹❺

13. Integration Step 1: Plot the Customer
Spec; in this case 0.870” ± 0.004”

14. Integration Step 2: Plot the Gage R&R
Estimate; in this case 7.6% of Tolerance

15. Integration Step 2: Plot the Gage R&R
Estimate; in this case 7.6% of Tolerance
At 7.6%, measurement error is in
the acceptable range and will not
distort the signal with noise.

16. Integration Step 3: Plot Stats from the T1
Samples; Assume All Cavities are Mixed

17. Integration Step 3: Plot Stats from the T1
Samples; Assume All Cavities are Mixed
With a Cp of 10.45 and Cpk
of 8.36, the T1 samples
show promising results.

18. Integration Steps 4 & 5: Plot Capability
Study Stats (±3 Sigma) from Every Cavity

19. Integration Steps 4 & 5: Plot Capability
Study Statistics from Every Tool Cavity
Capability studies of all 4 cavities
mirror the early T1 results.

20. Once Symbols Are Understood, Users
Learn to See Success in New Patterns
inside the customer spec’s goal posts
outside
outside

21. Bonus #1: Use an
Excel slider bar to
scroll through
every CTQ trait …
chart will auto-
matically vlookup
each trait’s spec,
R&R & cap studies.

22. Bonus #2: Use Excel lookup tables to pull
highlighted prints; assist PPAP users to
connect the print to capability data.

23. One Excel tab.
One chart plots
every element.
One slider bar
reveals all CTQs.
One lookup table
shows highlighted
areas of print.
Do.
Simple.
Better.