Industry Standards for # of parts for Capability Study and Layout FAI's?

T

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#1
What is your industry standard for the total number of pieces needed for Cap Studies and First Article Inspection parts?

We supply a range of customers and it varies. I am trying to set a standard of whats 'typical' for a business model.

Class '8' Truck - most require 30 piece capability and 1 piece FAI
ATV / Sports - require 100 piece capability and 5 piece FAI.

What is the statistical 'break point' for cost vs benefit? (on non-safety critical parts).
 
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Stijloor

Staff member
Super Moderator
#2
What is your industry standard for the total number of pieces needed for Cap Studies and First Article Inspection parts?

We supply a range of customers and it varies. I am trying to set a standard of whats 'typical' for a business model.

Class '8' Truck - most require 30 piece capability and 1 piece FAI
ATV / Sports - require 100 piece capability and 5 piece FAI.

What is the statistical 'break point' for cost vs benefit? (on non-safety critical parts).
Can someone help with this?

Thank you!!

Stijloor.
 
V

vardar3

#3
I submitted to FORD with a 30 pc run. Not only did I get rejected for trying to submitt PPAP off of a non-significant production run, but I was told from the STA that she would NEVER accept a PPAP that has capabality reports generated from 30 PCS.
-It was read to me from page 8 of the PPAP manual, and it was read to me from the FORD supplier manual. It was embarrassing.
 

Jim Wynne

Staff member
Admin
#4
What is your industry standard for the total number of pieces needed for Cap Studies and First Article Inspection parts?

We supply a range of customers and it varies. I am trying to set a standard of whats 'typical' for a business model.

Class '8' Truck - most require 30 piece capability and 1 piece FAI
ATV / Sports - require 100 piece capability and 5 piece FAI.

What is the statistical 'break point' for cost vs benefit? (on non-safety critical parts).
The idea behind a capability report (and what the automotive industry generally requires) is to do--where appropriate--standard control charts during a "significant production run," where "significant" depends on individual circumstances. The primary reason for this is to be able to establish at least a semblance of statistical stability before making any capability calculations. The chronological component is important in this regard.

There is a basic idea in statistics that in a normally-distributed population, the difference between the sample standard deviation and population standard deviation will approach being negligible when the sample size reachs 30. What this means in a general sense is that for many (certainly not all) populations, returns diminish with samples sizes >30. It's a dangerous generality though, with one reason being that an assumption of normality can be lead to unexpected outcomes.

Som how this misunderstood 30-piece sample idea became a sort of meme, with a lot of people believing that it makes perfect sense to calculate Cpk for a small sample that has been chronologically mixed. It doesn't, but the idea has taken on a life of its own, so it becomes one of the many time-wasters we have to put up with because of customers who don't understand what they're asking for.
 
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