Supplier Quality Requirements Supplement (SQR).

This manual is intended for use by Kohler Engines Division suppliers as a supplement to the
Kohler Co. Global Supplier Quality Manual. To verify the latest version of this document, go to http://www.kohlerengines.com/sqr/index.htm. To
access the Kohler Co. Global Supplier Quality Manual, go to www.kohler.com; Suppliers; Conducting Business.

Appendix C Revised 12/1/2012

PPAP Forms
The forms contained in this workbook are intended for use
by Kohler Engine Division outside suppliers and provided here for their convenience.

Appendix C, SQR
 Production Part Approval Process Checklist
PART NUMBER REVISION ENG. DATE
PRODUCT DESCRIPTION SUBMISSION LEVE
SUPPLIER KOHLER BUYER
REVIEWED BY DATE E-MAIL
DOCUMENTATION YES NO YES NO
N/A *** FOLLOWING ARE FOR LEVEL 3 *** N/A
PASS FAIL PASS FAIL
WARRANT PROCESS FLOW DIAGRAM
Correct Part Number Kohler Part No. included in Heading
Correct Rev. Level of Part Number Process Follows a Logical Sequence
Correct Date of Rev. Level Include all steps in the order that is actually occurs
Correct Customer Identify all controls used for key characteristics
Correct Reason For Submission DESIGN FMEA
Correct Submission Level Kohler Part No. included in Heading
Address all Areas of Design Requirements
Dimensional, Material/performance, Appearance
& Statistical studies Boxes Checked as Applicable
Submission Results Checked (Yes or No) Action Plan for Failure Mode with higher RPN
If Submission Results checked as No, explanation
added PROCESS FMEA
Signed & Dated By Supplier Representative Kohler Part No. included in Heading
DRAWING Address all areas in Process Flow Diagram
Are Kohler Prints submitted? Complete With All Potential Failures
Correct Revision Level of Engineering Change Action Plan for Failure Mode with higher RPN
Marked up print signed/dated by Kohler
Engineering PROCESS CONTROL PLAN
Kohler Engineering approval for non-Kohler
Prints Kohler Part No. included in Heading
All dimensions and requirements are numbered All critical/major requirements controlled
FULL INSPECTION REPORT Failure modes with higher RPN controlled
Kohler Part #, Rev. level are in the Heading CAPABILITY STUDIES
Tooling/cavity # is in the Heading Capability studies for all critical/major dimensions
Characteristics are numbered linking to the print Pre-production run size equals or > 300
1 sample per cavity, or 3 samples for single Sample size N=>100, or explained when using
cavity/fixture or other processes N<100
All Dimensions and Requirements are Inspected Critical/majors are 100% inspected when N<30
Inspection Points Disposition (PASS/FAIL) Histogram charts submitted and analyzed
Process capable (Cpk>1.67 for critical &
All Inspection Points Passed Cpk >1.33 for major)
Signed & Dated By Supplier Representative Action plan for each unacceptable Cpk
MATERIAL/PERFORMANCE TESTING GAGE R&R
Kohler Part # included in Heading Gage R&R's performed on PPAPed parts
Material Certifications signed & dated Conclusion and the criteria are given
Performance Report Submitted Action Plan for High GR&R Ratings
Test data or certificates less than 1 year old

Material made to the same or equivalent standard

Meets Chemical requirements COMMENTS
Meets Physical requirements
Meets Metallurgical requirements
All Specified Materials certified
APPEARANCE INSPECTION REPORT
Kohler Part No. included in Heading
Color matching certificate included
All color/texture/surface finishing/visual req. PASS

Appendix C, SQR
MEETS PACKAGING SPECIFICATIONS

Appendix C, SQR
 Incoming Material Packaging
Specification Checklist

Part Kohler Part Current

Number: Name: Revision:

Supplier
Project Submission
Supplier: Engineer: Date:

Palletizing
Material is Palletized

Maximum size of pallet 35" High x 42" wide x 42" long

Minimum size of pallet 36" wide x 36" long

Material overhang not permitted

Material must be secured to pallet

Labeling and Bar Coding

Minimum of 2 labels, on one end and one side per pallet

All Cartons must meet:

Kohler Incoming Material Packaging and Labeling Specification

Carton Requirements

Should not exceed 35lbs. (15.8kg.)

Should not exceed 18" wide x 15" deep x 10" high (45.7cm x 38.1cm x 25.4cm)

Hardware items not to exceed 9.5" wide x 9.5" deep x 10" high

(24.1cm x 24.1cm x 25.4cm)

NOTE TO SUPPLIERS: Shipments of material covered by this specification not in conformance

are subject to rejection and return to the vendor at their expense for repackaging. Any exceptions
to the above must have written approval of the Purchasing Manager of the individual plant.

Appendix C, SQR
 PART SUBMISSION WARRANT
Part Name Part Number
Material Type Machine No. Tool No.
Safety and/or Government Regulation Yes NO Rev. Level of Part# Dated
Shown on Drawing No. Weight kg.
Checking Aid No. Engineering Change Level Dated
SUPPLIER MANUFACTURING INFORMATION

Supplier Name Supplier Code

Customer Name/Division

Street Address Buyer/Buyer Code

City/State/Postal Code Application

REASON FOR SUBMISSION (Check one)

Initial Submission New designed tooling or tooling replacement

Engineering Change(s) Process or method changes

Material source changes Parts Produced at Additional Location

Tooling transfers or refurbishment

Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)
Level 1 -For minor engineering change only, see SQR 4.2.1.
Level 2 -For non-critical/major parts only, see SQR 4.2.2.
Level 3 -Sample parts plus Level 4 documents and reports.
Level 4 - For critical/major parts, see SQR 4.2.3.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria Process Capability Studies

These results meet all drawing and specification requirements. YES NO (If "NO" - explanation required)
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable
customer drawings and specifications and in the case of production samples, are made from specified materials on regular
production tooling with no operations other than the regular production process. I have noted any deviations from this
declaration below:

Explanation/Comments:

Print Name Title Phone

Fax: E-mail:

Supplier Authorized Signature Date

FOR KOHLER SUPPLIER QUALITY USE ONLY
Part Disposition Approved Rejected Interim Approval Until:

Appendix C, SQR
 Approved Rejected Interim Approval Until:

Kohler SQE SQE Signature Date

Appendix C, SQR
SUPPLIER PART NUMBER / PRINT NUMBER REV.

DATE
TOOLING/CAVITY NUMBER PART NAME

SC/ GAGE NAME/ QTY NOT

ITEM DIMENSION / SPECIFICATION MEASUREMENT RESULTS OK
CC NUMBER TESTED OK

SUPPLIER SIGNATURE TITLE DATE

Appendix C, SQR
Appendix C, SQR
 Production Part Approval Process-Material/Performance
Test Results
SUPPLIER PART NUMBER REVISION

NAME OF LABORATORY PART NAME

QTY SUPPLIER TEST RESULTS & TEST

ITEM REQUIREMENTS TESTED CONDITIONS OK NOT OK

SIGNATURE TITLE DATE

Appendix C, SQR
Appendix C, SQR
 PROCESS FLOW DIAGRAM

Part Number: Date (Orig.):

Part Description: Rev. Date:

Core Team:
Fabricate

Inspect

Key Product
Move

Store

Step Operation Description

Characteristics

u l D n

Appendix C, SQR
 PROCESS FLOW DIAGRAM

Part Number: Date (Orig.):

Part Description: Rev. Date:

Core Team:
Fabricate

Inspect

Key Product
Move

Store

Step Operation Description

Characteristics

u l D n

Appendix C, SQR
 Key Control
Characteristics

Appendix C, SQR
 Key Control
Characteristics

Appendix C, SQR
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA)
System Sub-System Component FMEA NUMBER

Item Design Responsibility Prepared By

Model/Application Key Date FMEA Date(Orig.)

Core Team FMEA Date(Rev.)

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

Appendix C, SQR
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)
FMEA NUMBER

Item Process Responsibility Prepared By

Engine/Application Key Date FMEA Date(Orig.)

Core Team FMEA Date(Rev.)

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

Appendix C, SQR
 CONTROL PLAN
Prototype Pre-launch Production Key Contact/Phone Date (orig.) Date(rev.)

Control Plan Number

Part Number/Latest Change Level Core Team Customer Engineering Approval Date (If Req'd)

Part Name/Description Supplier/Plant Approval Date Customer Quality Approval Date (If Req'd)

Supplier/Plant Supplier Code Other Approval/Date (if Required) Other Approval/Date (if Required)

Part / Process Characteristics Special Methods

Machine, Device, Jig, Sample
Process Name/Operation Char. Product/Process Evaluation/Measurement
Tools for MFG.
Number Description Number Product Process Class. Specification/ Tolerance Technique Size Freq. Control Method Reaction Plan

Appendix C, SQR
 Appearance Approval Report
PART NUMBER DRAWING NUMBER APPLICATION

PART NAME BUYER CODE E/C LEVEL DATE

SUPPLIER NAME MANUFACTURING LOCATION SUPPLIER CODE

OTHER
REASON FOR SUBMISSION
PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION
PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
APPEARANCE EVALUATION
SUPPLIER SOURCING AND TEXTURE INFORMATION
CUSTOMER REPRESENTATIVE
PRE-TEXTURE EVALUATION
SIGNATURE & DATE

CORRECT AND PROCEED

CORRECT AND RESUBMIT

APPROVED TO TEXTURE

COLOR EVALUATION
METALLIC COLOR
COLOR TRISTMULUS DATA MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS BRILLIANCE SHIPPING PART
SUFFIX DL* Da* Db* DE* CMC NUMBER DATE TYPE SOURCE RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW SUFFIX DISPOSITION

COMMENTS

PHONE DATE DATE

SUPPLIER CUSTOMER REPRESENTATIVE SIGNATURE

SIGNATURE

Appendix C, SQR
 Rev Date Change Changed By
Rev B 2/7/2007 Removed actual Design & Process FMEA forms and added a link to the D Hart
Masters for each
Rev C 7/3/2007 Delete TA-2, Add PPAP 14 A Pflughoeft
Rev D 7/5/2007 Delete PPAP Dimensional Tab, Add PPAP 102 tab L Truss
Rev E 3/10/2008 edited PPAP 15 form L.Truss
Rev F 8/29/2008 Added PPAP 16 Packaging spec checklist, added packaging spec to L.Truss
check list.
Rev. K 12/4/2008 Moved Supplier Request for Change and Packaging and Labeling Spec L. Schultz
and Checklist from this appendix to their own appendices. Added
Packaging checklist, DFMEA and PFMEA forms.

Rev. M 12/1/2012 New Dimensional Results Form. Added Material Type, Tool No., and L. Schultz
Machine No. to the Warrant.

Appendix C, SQR