Dimensional report (PPAP / AS9102)

Method

• Rows come from the PFMEA: every product characteristic (on a process step function) of the PFMEA is a row, with its classification and specification; tick Include process characteristics to add the work elements' process characteristics too. The measurement method starts from the evaluation / measurement technique of the characteristic's control plan row in the Production phase (empty when the plan has no row for it).
• Out of sync: each row remembers what the PFMEA and the control plan said at the last synchronisation. When they say something else now, the row is marked and its detail shows what changed. Sync with PFMEA updates changed rows, adds rows for new characteristics (after the last row of their operation, with the next free balloon number) and removes rows of characteristics that are gone. A row that already holds results, a location, tooling, a nonconformance number or comments is never deleted by synchronisation: it becomes an own row marked “kept”. A requirement or method you edited stays as you wrote it; unedited ones follow the PFMEA.
• Own rows: drawing dimensions the PFMEA does not hold (outline, holes, positions, notes) are added as rows of the report; synchronisation never touches them.
• Balloon numbers: new rows get one above the largest whole number in use. Numbers can be edited (e.g. “12.1”); a number used twice or a missing number is flagged. Renumber balloons sets 1, 2, 3 … in the order of the rows.
• Requirement: nominal ± tolerance (a trailing % means percent of the nominal), nominal with signed upper and lower deviations, lower and / or upper limit (one-sided allowed), or a text requirement such as “No burrs” or a GD&T note judged by hand. The PFMEA specification is read into this form where it is clear (“245 ± 5 °C”, “3.2 +0.1/0 mm”, “60–90 s”, “≤ 24 h”); anything else, also a strict “< 1000 ppm”, stays text.
• OK / NOK: a numeric result is OK when lower limit ≤ result ≤ upper limit: both limits are included. Limits and results are compared in decimal arithmetic at the digits typed, so 3.20 + 0.10 is exactly 3.30 and a result of 3.30 is OK. A point or a comma can be the decimal sign. Results of a text requirement are chosen by hand (OK / NOK). A characteristic is NOK when any sample is NOK, OK when every sample is recorded and OK, otherwise not measured or partly measured; a result that is not a number, or a numeric requirement without limits, is flagged instead of being judged.
• Samples: AS9102 records one actual result per characteristic; for PPAP the customer sets the number of parts (often five, or more per cavity). Up to 30 samples; the number cannot be reduced below a sample that holds results.
• Layouts: AS9102 Form 3 (5 char. no., 6 reference location, 7 characteristic designator, 8 requirement, 9 results, 10 designed / qualified tooling, 11 nonconformance number, 14 additional data / comments, with the method as an extra optional column) and PPAP dimensional results (item, dimension / specification, specification limits, test date, quantity tested, one column per sample, OK, not OK). These field numbers and titles were written from memory and are not verified against SAE AS9102 or the AIAG PPAP manual; check them before you submit a report.
• Output: Export XLSX writes both layouts as sheets (the chosen one first) and the whole project in a hidden sheet; results are written as typed text so the measured digits stay. Print / PDF prints the chosen layout, A4 or A3 landscape, with the header repeated on every page and page numbers in the margin (browsers without margin boxes print without them).
• Saving: this file stores nothing in the browser. Use Save JSON (or Export XLSX) to keep your work and Open… to continue. The file is the same project file as the PFMEA's and the control plan's.
• Limits: below 760 px width the report can only be viewed. The Excel file has no cell formatting. No statistics are computed here: for capability use the Cpk tool with the measured values.