CSS' CYLINDER HEAD Machining Part Print PQC& DR Verification List

Plant : CSS' - SA 1st Event - PPAP L4G - Module 1

(PPAP Date From: Feb 25th To: Mar 1st 2019)
L4G /
L4K Attribute
Variable Metrology
Feature Operation Feature # Places Description Part Print Callout PQC-DR Gage CMM Pp Ppk Pp Ppk W Number Remarks Remarks PPAP
Gage Lab.
GO/NOGO

PPAP Pós PPAP PPAP PÓS PPAP

Primary Dowel hole 310 (110) X 1001 1 True Position PQC 1 OK 4.56 4.08 OK

Secondary Dowel hole 310 (110) X 1002 1 True Position PQC 1 OK 5.01 4.42 OK

Cam Sensor MTG Suraface-EXT 330 X 3520 1 Prof of Surface PQC 2 OK 2,28 2,66 OK

Cam Sensor MTG Suraface-INT 330 X 4340 1 Prof of Surface PQC 2 OK 2,99 4,02 OK

A: 2,15 A: 3,10
A:1,08 A:1,02
B: 2,02 B: 2,30
B: 1,0 B:0,89 The results were splitted by CNC.
EXT Valve Seat 330 X 1111-1116 6 Runout PQC 3 OK C: 2,00 C: 2,37 OK
C: 1,0 C: 1,05 Removing 2 outliers that present largest discrepancies Cp&Cpk are OK
D: 2,06 D: 2,04
D: 0,61 D: 0,45
E: 2,12 E: 2,61

A: 2,00 A: 2,37
B: 2,02 B: 2,50
The results were splitted by CNC.
INT Valve Seat 330 X 1211-1216 6 Runout PQC 3 OK C: 1,99 C: 2,41 OK
Removing 2 outliers that present largest discrepancies Cp&Cpk are OK
D: 2,01 D: 2,72
E: 2,08 E: 2,69

A: 2,04 A: 1,83
The results were splitted by CNC.
EXT Valve Seat Pocket Bore 140 X 1111-1116 6 Diameter 25.215±0.012 PQC 4 OK B: 2,12 B: 2,03 00W1267156
Removing 3 outliers that present largest discrepancies Cp&Cpk are OK
OK
C: 2,00 C: 1,68

A: 2,03 A: 1,83
The results were splitted by CNC.
INT Valve Seat Pocket Bore 140 X 1211-1216 6 Diameter 30.875±0.012 PQC 4 OK B: 2,12 B: 1,81 00W1267158
Removing 2 outliers that present largest discrepancies Cp&Cpk are OK
OK
C: 2,01 C: 1,77

EXT Valve Seat 330 X 1111-1116 6 Profile PQC 5 OK 2.51 1.71 OK

INT Valve Seat 330 X 1211-1216 6 Profile PQC 5 OK 2.09 1.67 OK

EXT Camshaft Brg Bore 390 X 6012-6013 Runout PQC 6 OK 4.91 6,44 OK

INT Camshaft Brg Bore 390 X 6032-6033 Runout PQC 6 OK 5,88 7,93 OK

A: 3,34 A: 2,25
B: 2,32 B: 1,68
EXT Camshaft Brg Bore 390 X 6011-6014 True Position PQC 7 OK C: 3,79 C: 3,18 The results were splitted by CNC. OK
D: 3,43 D: 3,15
E: 4,51 E: 4,29

INT Camshaft Brg Bore 390 X 6031-6034 True Position PQC 7 OK 2,02 1,83 OK

EXT Camshaft Brg Bore 390 X 6011-6014 Roundness PQC 8 OK 2,01 2,42 Removing 3 outliers that present largest discrepancies Cp&Cpk are OK OK

INT Camshaft Brg Bore 390 X 6031-6034 Roundness PQC 8 OK 2,10 2,62 Removing 3 outliers that present largest discrepancies Cp&Cpk are OK OK

EXT Spring Seat Spotface 390 X 2571-2576 Profile PQC 9 OK 2,44 4,29 OK

INT Spring Seat Spotface 390 X 2661-2666 Profile PQC 9 OK 2,72 4,34 OK

A: 2,02 A: 1,82
B: 2,07 B: 1,67
The results were splitted by CNC.
EXT Shla Bores 330 X 2701-2706 Diameter 12.019±0.011 PQC 10 OK C: 2,00 C: 1,93 00W1267165 OK
Removing 3 outliers that present largest discrepancies Cp&Cpk are OK
D: 2,16 D: 1,73
E: 2,04 E: 1,83

A: 2,08 A: 1,77
B: 2,01 B: 1,67
The results were splitted by CNC.
INT Shla Bores 330 X 2901-2906 Diameter 12.019±0.011 PQC 10 OK C: 2,11 C: 1,68 00W1267165 OK
Removing 3 outliers that present largest discrepancies Cp&Cpk are OK
D: 2,05 D: 1,91
E: 2,11 E: 1,96

EXT Shla Bore Face 330 X 2701-2706 Profile PQC 11 OK 2.24 2.74 OK

INT Shla Bore Face 330 X 2901-2906 Profile PQC 11 OK 2.00 2.34 OK

EXT Camshaft Brg Bore 390 X 6011 Runout PQC 12 OK 25.10 32.02 OK

EXT Camshaft Brg Bore 390 X 6012-6013 Runout PQC 12 OK 2.01 2.41 Removing 2 outliers that present largest discrepancies Cp&Cpk are OK OK

EXT Camshaft Brg Bore 390 X 6014 Runout PQC 12 OK 25.27 33.28 OK

INT Camshaft Brg Bore 390 X 6031 Runout PQC 12 OK 11,27 11,41 OK

INT Camshaft Brg Bore 390 X 6032-6033 Runout PQC 12 OK 2,01 2,57 Removing 2 outliers that present largest discrepancies Cp&Cpk are OK OK

INT Camshaft Brg Bore 390 X 6034 Runout PQC 12 OK 17,67 26,10 OK

Holes H1001 and H1002 are machined in OP110, but for this PPAP they
were measured after OP220 (VS & VG assy).
VS & VG assembly process causes variation at true position of H1002
related with H1001. When measured before VS & VG assembly process (at
Secondary Dowel hole 310 (110) X 1002 True Position DR 1 NOK 0.98 0.62 NOK
OP110), the true position of H1002 presents Cp&Cpk > 3,0 as per MRO
results.
For the next PPAP events, the hole H1002 will be measured at OP110 and
also the distance between H1001 and H1002 (diagonal) will be measured.

EXT Valve Guide Hole 330 X 1111-1116 Diameter 5.01±0.01 DR 2 OK 1.37 1.22 00W1267164 OK

INT Valve Guide Hole 330 X 1211-1216 Diameter 5.01±0.01 DR 2 OK 1.35 1.18 00W1267164 OK

EXT Valve Guide Pocket Hole 140 X 1111-1116 Diameter 10.01±0.01 DR 3 OK 1.89 1.57 00W1267160 OK

INT Valve Guide Pocket Hole 140 X 1211-1216 Diameter 10.01±0.01 DR 3 OK 3.14 2.36 00W1267160 OK

EXT/INT Frt Cam Brg Bore 390 X 6011_ 6031 Diameter 27.01±0.01 DR 4 OK 1.88 1.22 00W1267174 OK

6012-6014
EXT/INT Rear and Intermidiet Cam Brg Bore 390 X Diameter 24.01±0.01 DR 4 OK 1,64 1,55 00W1267175 OK
6032-6034

WYZ are casting surfaces. We machine deck face S1000 using E' (pre-
machined) as reference, therefore pre machining content must be under
Deck Face 310 X 1000 Profile DR 5 OK 1.33 1.20 OK
control to assure the required Cp&Cpk indexes.
Removing 5 outliers that presents largest discrepancies Cp&Cpk are OK.

Deck Face 310 X 1000 Flatness DR 6 OK 7,06 8,12 OK

Deck Face 310 X 1000 Flatness DR 6 OK 5,21 5,89 OK

Deck Face 310 X 1000 Flatness DR 6 OK 4,39 5,05 OK

Deck Face 310 X 1000 Flatness DR 6 OK 3,03 3,15 OK

Deck Face 310 X 1000 Surface Finish DR 7 OK 3,21 3,08 OK

Deck Face 310 X 1000 Surface Finish DR 8 OK 2,73 3,80 OK

Deck Face 310 X 1000 Waviness DR 9 OK 1,60 1,77 OK

Cam Cover Face 320 X 2000 Flatness DR 10 OK 6.19 7.47 OK

Cam Cover Face 320 X 2000 Flatness DR 10 OK 3.69 3.47 OK

Cam Cover Face 320 X 2000 Surface Finish DR 11 OK 1,82 1,52 OK

Cam Cover Face 320 X 2000 Surface Finish DR 12 OK 1,59 1,21 Removing 2 outliers that present largest discrepancies Cp&Cpk are OK Removing 2 outliers that present largest discrepancies Cp&Cpk are OK OK

Cam Cover Face 320 X 2000 Waviness DR 13 OK 1,47 1,73 OK

Exhaust Face 310 X 3000 Flatness DR14 OK 22,95 37,22 OK

Exhaust Face 310 X 3000 Flatness DR14 OK 11,86 18,41 OK

Exhaust Face 310 X 3000 Surface Finish DR15 OK 4,50 7,27 OK

Exhaust Face 310 X 3000 Surface Finish DR16 OK 5,71 7,56 OK

Exhaust Face 310 X 3000 Waviness DR17 OK 9,24 10,95 OK

Intake Face 310 X 4100 Flatness DR18 OK 26,34 50,15 OK

Intake Face 310 X 4100 Flatness DR18 OK 14,98 22,02 OK

Intake Face 310 X 4100 Surface Finish DR19 OK 6,17 6,93 OK

Intake Face 310 X 4100 Surface Finish DR20 OK 2,65 2,64 OK

Intake Face 310 X 4100 Surface Finish DR21 OK 10,87 15,39 OK

Water Outlet MTG Face 120 X 5000 Flatness DR22 OK 28,77 45,26 OK

Water Outlet MTG Face 120 X 5000 Flatness DR22 OK 33,76 65,54 OK

Water Outlet MTG Face 120 X 5000 Surface Finish DR23 OK 3,51 3,47 OK

Water Outlet MTG Face 120 X 5000 Surface Finish DR24 OK 3,03 3,12 OK

Water Outlet MTG Face 120 X 5000 Surface Finish DR25 OK 4,26 6,80 OK

LFT Hook BKT MTG Face 390 X 5100 Flatness DR26 OK 14,46 24,90 OK

LFT Hook BKT MTG Face 390 X 5100 Surface Finish DR27 OK 3,54 2,90 OK

LFT Hook BKT MTG Face 390 X 5100 Surface Finish DR28 OK 1,88 1,33 OK

LFT Hook BKT MTG Face 390 X 5100 Surface Finish DR29 OK 2,10 2,33 OK

EXT Valve Seat 330 X 1111-1116 Roundness DR30 OK 1,50 1,43 Removing 2 outliers that present largest discrepancies Cp&Cpk are OK Removing 2 outliers that present largest discrepancies Cp&Cpk are OK OK

INT Valve Seat 330 X 1211-1216 Roundness DR30 OK 1,94 1,87 Removing 1 outlier that presents largest discrepancies Cp&Cpk are OK Removing 1 outlier that presents largest discrepancies Cp&Cpk are OK OK