Our Name: Adams Thermal Systems

Customer Name: Behr

Part Name:
Part Number:
Rev. Level:
Rev. Date:
Product Program:

Key Production Date:

LAST UPDATE
 PPAP
Customer Name: Behr
Part Name:
Part Number:
Rev. Level:
Product Program:

PSO Submission Date:

 Customer Name: Behr
PPAP Part Name: Part Number:
Rev. Level: Product Program:
0
Daimler Chrysler Part Submission Warrant
Part Name 0 Part Number 0
Safety and/or
Government Regulation Yes ✘ No Engineering Drawing Change Level 0 Dated 12/30/99

Additional Engineering Changes Dated

Shown on Drawing No. 0 Purchase Order No. Weight (kg)

Checking Aid No. Engineering Change Level Dated 12/30/99

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Adams Thermal Systems ✘ Dimensional ✘ Materials/Functional Appearance

Supplier Name & Supplier Code Supplier Code
Customer Name/Division Behr

Street Address Buyer/Buyer Code

MI Application 0
City State Zip

Note: Does this part contain any restricted or reportable substances. Yes ✘ No

Are plastic parts identified with appropriate ISO marking codes Yes ✘ No

REASON FOR SUBMISSION

✘ Initial Submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report ) submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

✘ Level 3 - Warrant with product samples and complete supporting data submitted to customer.

Level 4 - Warrant and other requirements as defined by customer.

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS

The results for ✘ dimensional measurements ✘ material and functional tests appearance criteria ✘ statistical process package
These results meet all drawing and specification requirements: ✘ Yes No (if "No" - Explanation Required)
Mold / Cavity / Production Process

DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable
Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were
produced at the production rate of / 8 hours. I have noted any deviations from this declaration below.

EXPLANATION/COMMENTS:

Print Name: Title: Phone No: Fax No.

Supplier Authorized Signature Date

FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition: Approved Rejected Part Functional Approval: Approved

Other Waived

Customer Name Customer Signature Date

July The original copy of this document shall remain at the suppliers location Optional: customer tracking
1999 CFG-1001 while the part is active (see Glossary). number: # _______________
 Production Part Approval ___
Daimler GM Dimensional Results
Chrysler
Page 1 of 4

SUPPLIER PART NUMBER

Adams Thermal Systems 0
NAME OF INSPECTION FACILITY PART NAME
0
NOT
ITEM DIMENSION / SPECIFICATION SUPPLIER TEST RESULTS OK OK

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
MAY CFG-1003 SIGNATURE TITLE DATE
1995
 Production Part Approval ___
Daimler GM Dimensional Results
Chrysler
Page 2 of 4

SUPPLIER PART NUMBER

Adams Thermal Systems 0
NAME OF INSPECTION FACILITY PART NAME
0
NOT
ITEM DIMENSION / SPECIFICATION SUPPLIER TEST RESULTS OK OK

23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
MAY CFG-1003 SIGNATURE TITLE DATE
1995
 Production Part Approval ___
Daimler GM Dimensional Results
Chrysler
Page 3 of 4

SUPPLIER PART NUMBER

Adams Thermal Systems 0
NAME OF INSPECTION FACILITY PART NAME
0
NOT
ITEM DIMENSION / SPECIFICATION SUPPLIER TEST RESULTS OK OK

45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
MAY CFG-1003 SIGNATURE TITLE DATE
1995
 Production Part Approval ___
Daimler GM Dimensional Results
Chrysler
Page 4 of 4

SUPPLIER PART NUMBER

Adams Thermal Systems 0
NAME OF INSPECTION FACILITY PART NAME
0
NOT
ITEM DIMENSION / SPECIFICATION SUPPLIER TEST RESULTS OK OK

67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
MAY CFG-1003 SIGNATURE TITLE DATE
1995
 Production Part Approval ___
Daimler GM Material Test Results
Chrysler
Page 1 of 1 Pages

SUPPLIER PART NUMBER

Adams Thermal Systems 0
NAME OF LABORATORY PART NAME
0
TYPE OF NOT
TEST MATERIAL SPEC. NO. / DATE / SPECIFICATION SUPPLIER TEST RESULTS OK OK

MAY CFG-1004 SIGNATURE TITLE DATE

1995 QUALITY MGR.
 PROCESS FLOW DIAGRAM

PART NUMBER: 0 MFG. ENG.:

PART NAME: 0 QUAL. ENG.:
CUSTOMER: Behr PLANT MGR.:
E.C.L.: 0

tl n REV. DATE: 11/18/04

Operation

Inspect Tool / Gage / Fixture /

Operation Description Key Product / Process Characteristics
Location / Operator
Move

Store
Step

10

n Incoming Inspection
20
Store Material
30

l Move To Press
40

t Load on Uncioler
50

t Straighten
60
t Oil
70
t Form
80

n Inspect
90
t Pack
100

l Move to Shipping
110
Store in Shipping
120
l Ship

OPERATOR KEY
TD TRUCK DRIVER MO MACHINE / PRESS OPERATOR
MH MATERIAL HANDLER / HI-LO AO ASSEMBLY OPERATOR
ST STOCK / STORAGE RC RECEIVING CLERK
PT PROCESS / PRESS TECHNICIAN QA QUALITY INSPECTOR

Flow10/26/2009 Page 11 of 23
 FAILURE MODES EFFECT ANALYSIS

PART NAME AND NUMBER: / PROCESS RESPONSIBILITY: FMEA DATE (ORIG.): 1/4/2005
Rev Level/Date KEY PRODUCTION DATE: FMEA DATE (REV.):
CORE TEAM MEMBERS: MODEL YEAR(S) / VEHICLE(S): PREPARED BY:

PART NAME: MODEL VEHICLE:

Current Process Controls D Action Results
C O
S Potential E
Potential Potential S L C R Responsibility
T Process Cause(s)/ T Recommended
Failure Effect(s) of E A C P & Target
E Function Mechanism(s) E Action(s)
Mode Failure V S U N Completion Date S O D R
P of Failure Prevention Detection C Actions
S R E C E P
T Taken
V C T N

10 Incoming Incorrect material - Non Conforming 4 Wrong Material 1 Check at receiving 1 4

Dimensional Product Shipped to ATS
Inspection
Incorrect alloy Braze Problems at 8 Wrong Material 1 Check Material 1 8
Behr Shipped to ATS Certification
40 Load Coil on Incorrect material - Non Conforming 4 Wrong Material 1 Check at Press 1 4
Dimensional Product Shipped to ATS
Uncoiler
Clad on Wrong Side Braze Problems at 8 Material Clad on 1 10 80
Behr Wrong Side
50 Straighten Material not Straight Die Feed Problems 2 Not Set Correctly 2 2 8
into die
60 Oil Crakcing/ Thinning of Leaks on Assembly 5 Oiler not working/ 2 Visual inspection 8 80
material empty
Parts stick in die Non conforming 3 Oiler not working/ 4 Die problems 1 12
Product- Dimensional empty
Burrs on part Non conforming 3 Oiler not working/ 4 Visual inspection 8 96
Product- Dimensional empty
Oily Parts Braze Problems at 6 Oiler set too high 2 Visual inspection 8 96
Behr
70 Form Progression set Incorrect Part Width/ 6 Incorrect Progression 2 Part Layout 2 24
incorrectly Collar Ht.
Die Shut Ht. Incorrect Incorrect Collar Ht 6 Die shut Ht. set 2 Part Layout 2 24
and Part Flatness incorrectly
Die Worn/Broken Non conforming 6 Die/Worn Broken 2 Die PM System Part Layout/ 2 24
Product- Dimensional
90 Pack Wrong Part # on No Build at Behr 8 Incorrect label 3 8 192
Container installed
Wrong "Born on Date" Braze Problems at 8 Incorrect Date 3 8 192
Behr samped on Container

KB Stamping FMEA 11/1/04 Page 12 of 23

 FAILURE MODES EFFECT ANALYSIS

PART NAME: MODEL VEHICLE:

Current Process Controls D Action Results
C O
S Potential E
Potential Potential S L C R Responsibility
T Process Cause(s)/ T Recommended
Failure Effect(s) of E A C P & Target
E Function Mechanism(s) E Action(s)
Mode Failure V S U N Completion Date S O D R
P of Failure Prevention Detection C Actions
S R E C E P
T Taken
V C T N

10 Incoming Incorrect material - Non Conforming 4 Wrong Material 1 Check at receiving 1 4

Dimensional Product Shipped to ATS
Inspection

KB Stamping FMEA 11/1/04 Page 13 of 23

 KB Stamping
8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
SUPPLIER LOCATION: FIRST ISSUED:
SUPPLIER PHONE: REVISED:
PROCESS CONTROL PLAN
SUPPLIER CODE: SUPERCEDES:

KB STAMPINGS REP. CUSTOMER REP. (IF APPLICABLE)

PART NUMBER/E.C.L.: PROTOTYPE PLANT MGR.: _____________________ DATE: _____________ Q.A. REP.: ___________________________ DATE: _____________
/
PRE-LAUNCH MFG. ENG.: _______________________ DATE: _____________ ENG. REP.: __________________________ DATE: _____________
PART NAME:
0 PRODUCTION Q.A. MGR.: _______________________ DATE: _____________ MGMT. REP.: _________________________ DATE: _____________

Part Name Model Vehicle KB NUMBER:

Characteristics Methods
Process Machine,
Part/ Special
Name/ Device,
Process Char. Product/Process Evaluation Sample Reaction Plan ACTUAL MEASUREMENT
Operation Jig, Dies
Number No. Product Process Class Specification/ Measurement Control Method
Description For Mfg.
Tolerance Technique Size Freq.

Rec

Insp

KB Stamping Production Control Plan 11/1/04 Page 14 of 23

 KB Stamping
8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
Part Name Model Vehicle KB NUMBER:
Characteristics Methods
Process Machine,
Part/ Special
Name/ Device,
Process Char. Product/Process Evaluation Sample Reaction Plan ACTUAL MEASUREMENT
Operation Jig, Dies
Number No. Product Process Class Specification/ Measurement Control Method
Description For Mfg.
Tolerance Technique Size Freq.

10

20

30

KB Stamping Production Control Plan 11/1/04 Page 15 of 23

 KB Stamping
8110 Graphic Dr.-Belmont, MI. 49306
Phone:(616) 866-5917 Fax: (616) 866-5918
Part Name Model Vehicle KB NUMBER:
Characteristics Methods
Process Machine,
Part/ Special
Name/ Device,
Process Char. Product/Process Evaluation Sample Reaction Plan ACTUAL MEASUREMENT
Operation Jig, Dies
Number No. Product Process Class Specification/ Measurement Control Method
Description For Mfg.
Tolerance Technique Size Freq.

KB Stamping Production Control Plan 11/1/04 Page 16 of 23

 Production Inspection Sheet

Check 1st piece at set-up or start of day and record data.

Check 1 part at the start of each coil & 1 part per bin
Check Last piece from Production Run, Record Data, Attach last & 1st piece part to fixture
Shut down and notify Management of any non conformance
Print Rev.: Rev Date: Customer:
0 12/30/99 Behr
Part Number: Part Name Lot No.: Date:
0 0
Print Specification &
Sample No. 1 Sample No. 2 Sample No. 3 Sample No. 4 Sample No. 5
Characteristic

KB Stamping Production Inspection Sheet 01/27/03 Page 17 of 23

 OPERATION INSTRUCTIONS

PART NAME: 0 OPERATION(S): 10 Progressive Complete ISSUED BY: DATE:

PART NUMBER: 0 APPROVED BY: DATE:
KB JOB NUMBER: 0

WORK STATION OPERATION METHOD PACKAGING INSTRUCTIONS

OPERATOR

1) VERIFY MATERIAL THICKNESS PRIOR TO LOADING

MATERIAL INTO DIE.

OP. 10 2) WHEN LOADING MATERIAL INTO DIE, ASSURE THAT

PRESS CONVEYOR TO
DIE CARDBOARD BOX IT IS ALIGNED "PARALLEL" TO THE DIE.

3) WHEN THE MATERIAL IS COMPLETELY LOADED,

PERFORM LEAD CHECK TO ASSURE SHUT HEIGHT.

BOX FIRST PIECE 4) WHEN FIRST PIECE IS APPROVED, RUN PRESS IN

AND IN
PROCESS
FULL AUTOMATIC MODE.
INSPECTION
5) MONITOR SCRAP REMOVAL SO THAT IT DOESN'T Place packaging picture here
AFFECT DIE.

GAGE
6) WHEN THE CONTAINER IS FULLACCORDING TO
TABLE
PACKAGING INSTRUCTIONS.
FINISH GOODS SKID
7) APPLY COMPLETED PRODUCT INVENTORY LABEL TO
SKID.

QUALITY CRITERIA GAGE INSTRUCTIONS

7) USE FEELER GAGES
TO VERIFY PROPER
FORM / FORM
LOCATION AS SHOWN
ON FIXTURE.

Place part picture here

5.

1) PLACE CENTER HOLE OVER 12.0 - 12.2 MM GO / NOGO

PIN TO VERIFY CORRECT SIZE. 8) USE YELLOW
SCRIBE LINES TO
7.
2) PLACE CENTER SLOTS (2) OVER 12.2 - 12.4 X 5.30 - 5.50 VERIFY PROPER TRIM
MM GO / NOGO PIN TO VERIFY CORRECT SIZE. LOCATIONS.

3) PLACE HOLES (2) OVER 4.7 - 4.9 MM GO / NOGO PIN TO

VERIFY CORRECT SIZE.

4) CLAMP PART ONTO FIXTURE

8. 6.
5)
INSERT 11.80MM STAB PIN INTO CENTER HOLE TO
VERIFY POSITION

6) REMOVE STAB PIN, TURN OVER AND INSERT 12.00 x 5.10

STAB PIN INTO EACH SLOT TO VERIFY POSITION

FREQUENCY: FIRST PIECE, EACH COIL CHANGEOVER, BEGINNING OF EACH CONTAINER, AND AFTER ANY MACHINE OR DIE ADJUSTMENTS.
RECORD ACCEPTANCE STATUS ON PRODUCTION INSPECTION SHEET.
 DIE SETUP SHEET

KB JOB NUMBER: 0 ISSUED BY: DATE:

PART NAME: 0 APPROVED BY: DATE:
CUSTOMER: Behr

SUBJECT REQUIREMENT
PRESS SIZE
STOCK (MATERIAL) SIZE
COUNTER BALANCE PRESSURE
SHUT HEIGHT
FEED ROLLER PRESSURE
MATERIAL FEED DISTANCE
MATERIAL FEED RATE
STRAIGHTENING PRESSURE
PILOT RELEASE PRESSURE
STROKES PER MINUTE
OIL (LUBRICANT)
AIR HOOK-UP Place picture of die in press here….
SENSOR HOOK-UP

DIE PROTECTION ON OFF

SHORT FEED
PART EJECT

CAM SWITCH ON OFF

FEED ADVANCE
PILOT RELEASE

TONNAGE REFERENCE
DIE LOCATION TONNAGE
LEFT FRONT
LEFT REAR
RIGHT FRONT
RIGHT REAR
TOTAL TONNAGE

SHAKER REFERENCE
TYPE SIZE LOCATION COMMENTS

1. ASSURE SHUT HEIGHT BY PERFORMING LEAD CHECK.

2.
3.
4.
5.
6.
 Item ID Item Description
1
2 Micrometer 0-1" Mic - Material Thickness Verification
3 Tape Measure Tape - Material Width Verification
4
5
6
7
8
9
10
 SPECIAL CHARACTERISTICS LIST
PART NAME: PART NUMBER:
No. Description/Rationale Specification/Tolerance Class. Illustration/Pictorial
1 -
2 -
3 -
4 -
-

Form Revision: 11/3/04 Page 21 of 23

 Predictive Maintenance Check List
Die Number: 0 Date: C
o
Indicate cycle m
p

100,000
150,000
200,000
250,000
300,000
350,000
400,000
450,000
500,000
l

50,000
Do all activities marked e
t
Cycle Frequency with an "x" e

Punch/Bull Ring Mounting x x x x x x x x x x Check/tighten screws

Wear Plates x Return to original sizes
Storage Cushions x x x x x x x x x x Check and/or replace
Balance Blocks x x x x x x x x x x Check and/or replace
Information Weight x x x x x x x x x x Check for Legibility
Tags Nitro Pressure x x x x x x x x x x Check for Legibility
Danger x x x x x x x x x x Check for Legibility
Guidance Guide Pins x Check for wear, replace
Guide Bushings x x Check for wear, replace
Lifters x x x x x Check for leaks
Cylinders x x x x x Check for leaks
Prox. Switches x x x x x x x x x x Check
Cords x x x x x x x x x x Check
Boxes x x x x x x x x x x Check
Surface Wear Cavity/Pad x x Check for surface damage
Punch x x One or
Post x x the other
Plate type x x x x x x x x x x Check for damage
Pin type x x x x x x x x x x Check for damage
Punch Rubbing x x x x x x x x x x Check for damage
Nitro x Check Nitro Log and/or replace
Air x Replace
Internal Wear Plates x Return to original sizes
Pad Pins & Bushings x x Replace bushings/check pins
Gauging Rail Gauge x x x x x x x x x x Check for tight/position/damage
Solid Gauge x x x x x x x x x x Check for tight/position/damage
Bottom Blocks x x Check for tight/position/damage

"X"= Done. 0 = no action needed. NA = not in this die.

Legend for complete column

Comments:
Actual Time Spent

Checklist Completed By:

 PREVENTIVE MAINTENANCE WORK INSTRUCTION
Control Object: Use of this instruction will enable the Die Preventive Maintenance Areas to warrant the
tools that have been PM'd as fit for service when returned to their production line.
Reason: This instruction serves as a reminder to the die maker to check critical areas on the
tools and repair/replace those areas that may be a problem during a production run.
Responsibility: The die maker will perform this maintenance before returning the tools to production and
inform the supervisor of any problem that requires scheduled release time to correct.

Instructions:
1) Check punch and resurface as needed

2) Check upper and lower Steels for wear. Repair as needed.

3) Check beads and gutters for wear. Repair as needed.

4) Check nitro cylinders for leaks. Replace as needed

5) Check lifter system for damage. Repair as needed

6) Check heel and wear plates for proper clearance and wear. Tighten/replace as needed.

7) Check risers and punch mounting plates for loose and missing screws.
Tighten/replace as needed.

8) Clean disassembled die. Lubricate where necessary.

9) Check and re-size / re-shim equalizer blocks.

10) Check bolster plate mounting screws. Tighten/replace as needed.

Approval: Date:

Concurrence: Date:

Date Revised: Date Issued: