A-l DESIGN FMEA CHECKLIST Ccmamarcrintomal Path. NUMBER Quostion ‘Comment / Action Required [sate SFuEA stale DPVEAsrserauare ‘Dariechivaur rove apa Cores Mars ot our aera tee arabes 7 ve hsorenconcaan ara ware Gaia bea] pease” 3 fs spot EE eee 4 Posse SrA noo CRVEA ont Socal ve cragn cracls Nalaroa TGnTar ‘phar roses tenn Gert ied © fis copronrarsorecte aera sean sgrestorigh' sey nuTees? 7 Pisvesopon ale mrectieachons team gone onghsevare unten 7 fe Ta probes bee ered eT aE recta By A-2 DESIGN INFORMATION CHECKLIST Cartrnrrnkra Pas No, NUMBER. ‘Comment / Action Recuired Porson [ous Dat Question Ree Genera Te ten meters eo a redoed? he Deg Ven Pa DST rasta [as aoa soe Sasa loos" i 7A-2 DESIGN INFORMATION CHECKLIST ‘Question ves] No ‘Comment | Action Required Person Responsible Joue Date] [esate oy B,Enginecrng awn Fieve omensons rat ec, acinar [sity coerce fr riccroe omens GerateaTa RMSE [reoetontyouthna? eficent cra poneand Signa [eethest denn urctond sees? ers as conpele nh frendscuvasenceras? [esters ary roqurorerta peated cone, osevacarcauenginown repocrer tna] ‘Enginesrng Peormanee Seecticaions Jroveaimeca crwacinsca van certeg? |sexmeangsneetioscsea arators Jes eccvctorwlaston anserc use? hoe pare man docures triamum so [cor scctons eamciee be eatac wrens eeaay perroauroa anes coraust odor [erecdedroracesstas” ‘A-2 DESIGN INFORMATION CHECKLIST ‘Custer or ein PartNo, NUMBER Quvstion Yes] No ‘Comment / Action Roguited Person Rosponsible | [ritarprccia ara beens noe site spafostostsomovoscs rae froair0s,nascintire soso BeOS ‘Miata Specealon Pre specal maeraichararienSiceGeTOIEST fresmees compatte wn reaurably [scuramers nine enron orenent? lavsomer sports” |eivcaion wien stiomint ve rseralcnracersico wa 05 RaDSST lssoncorenac? i, are ATE STOIC + esau prea ISBTA-2 DESIGN INFORMATION CHECKLIST Customerarniemal Patho NUMBER: Person Question res] No] Comment ction Resuired | gehertaiyg [ue Dat =a as Tae OTTO ea Raa TRAST OT BY tea =p soe = Emin A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST ane inal Pa, NVEER Question res] no] Comment Action Required | yt, [ove Oaid nee TY new rea a © MR STP? Fane bee pases TS + New espe T Newton? as oes ct bon opsecuBOTEE New eu emere? T New ena Ts pannay Spit aaybecenaaal feted sre easement aula Jeztares? YA-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST ustonerarinera Pate, NUMER Person Question [Yes] No] Comment! Action Required | persevere [OUe Date Ta Sete EET aaa cogs aaa? Thican conan omen] bsaracanetsnriccaan! [iesomealoa ncrarsctscabesn cere? [seems a Ta esas rerutocurra oqusmen nave [etosricoct ie nmcb erento rece Bo tena canst sVTER To orae eau Presa by ‘Acd PRODUCTIPROCESS QUALITY CHECKLIST ‘ousareror itemal Patho NUMBER Person Question [ves] No] Comment? Action Required | reson [ste Se Toe [ssvenes or ross engrosnng oy nesses [edevcoper conse oitecanialpon? F [Fas he mpcie centea who wate Teaco eo lisson wens susie T Pres he anit seuronce sein beep ee | snare ermerchrae Ford ora Gora! [voters Sytem Bae ‘streetcar parse ierifago coer © Ceres eaurerer™ 7 [= Ereeiig pataaee eT Treen aan ae ites deooresies ng DOSED B= imteesst ewwosees? T[s Faas angen? Fes Wang boos congas W]e Siesen ses corre”‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST customer erntral Pa Ne, NUVEER Person Rosporsible Ue Date] Question Yes] No| Comment Action Required T+ ame sas Tee WainepeaT TE [+ Grer apes Barat? [rstuctons to koe ts he coral? len cpear” De inoeion nections pele [gE pirgenen eerste Te teattear oe? ae Tipe Remsen sae Be css wean ‘A-d PRODUCTIPROCESS QUALITY CHECKLIST ‘Customer oil Part, NUMER : mana | Canton ex] to] cement acon ewsied | 5 PS, [be Oa] 7 haat Toe ay |zractonesctonsoetarauieton contd [steel a eT] lice” 7 racnomusben nas boasts Gee [sews naspechcstens ibe somcalte Jespecion? [ie arlege alee serosa losers nesion ree ave sovsirs been ads Wace a Gioug & he maT Ti] = Tepecionosaes? [> Capea E] Ranma re Tepecion oe TE [Pasaovaarsvonn nace Bost we [inal caer gages nc test exon? ave gute memset stem ey SESS De BY ° conices?‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST ‘ousomer or itemal Par he NUMER Question Yes] No ‘Comment Action Required Person Responsible ue Date Bye ney a ane ongeng ayo of There smears er conPa ng OTT HOS Ta aT aj + Cnmaciesteslote nsseded? 3] a] 7 Sapo nat 2 ee 7 Dapoatan a rocatamina SEES? [stares nomarsr ont cosas SP [cra rorcorternra reaudstooment [reravonapar penuwS STE af] [sttereaoncmouerereauaty [poradrewotes maions”™ [= rere on apzoorete et TaRSBTY HOSA [ee retmened? [fe scaae aa Tougory SaaS So laresaramacnene [Sectester? “ee A 5 FLOOR PLAN CHECKLIST ves] No ‘Comment Action Required Person Responsible ou Date Tes pa ae th a eaaea Om inspectonaotes? fequomiret oo" aperten Baan seas! Foro ceany marvacarasta al nail BOS re rocess os noo RE TT] > Oracousiesee” = Fo ‘ier? Proteremeaa TineaA-SFLOOR PLAN CHECKLIST Customer ar niema Pa No RULER vestion ves] No] Comment/ActionReauired | pettiehg Jove Dard incinied esi eet TS Pre cattas sasquae fo revert moveroTTaT feorerranconra realm seransor Prepares By A-6 PROCESS FLOW CHART CHECKLIST ‘cusomer erintomalPan Ne. NUMEER Person Rosponsibie |Oue Dat} ‘Question [ves] No] Commont / Action Required 1 Presi ton nar hate hessueneor rasueien ora rssecbon Sahara Z Jer at ororprae PUES (FUER OPTED, frspe revo hed poll before boing used? 7 Pins paetat gusty polar su nansirg doula pocess best aefid snaA-T PROCESS FMEA CHECKLIST ‘store oer Pat No NUMBER Question ves] ‘Comment/ Action Required Person Rosponsibie Joue Dar 1 [imate Poco eAnresmatuaraine Sige: ford an Goneracos auvaree? Z soalosentorestectra tt ncn abt, goverment roguiore on atcy niverwfes snaletssoarcaly? Ties pel ERS mend 7 sre snpasrau cored ctorabom panned an forrigh tcanety Eom? se sspmaratscorecive actors bemoaned | Sroawe son woscamaoa? 7 Jase ngh anerty umber reyeadunena nerarae oe comDitod 7 panecteascowaarrecanre Temes te abeeavoriopesien acer. and oo [rnin g he Perma FMEA? 7 [ue cusoner sin pobens sadasanauh [vst he one MEA? * onemigratcanbe ed orcemonac ee eraga ol custaret ern Pat Na NUVEER A-8 CONTROL PLAN CHECKLIST Question Yes] No ‘Comment / Action Required Porson Responsible Jove Dat| [Restecorvotaon netomeay ch mean [Secovswesinoreamrng ne or pan Fev alrcyn costore cvearisbeen Jocctinsicfetinietne vaste oes 7 [Reo seca erosucte ccesscrracenes [ried isine cor ao 7 Pies SeVEA CREA ss PERSO aparece a F [ue catetal ect calor Sag NSTON loses” * |reveottameorerts teugh [pocesngamerornawia anes? 7 [ResngnesTasatomane ira foasroneastaurtsa? T [Recagesand estos pneT aime feairesoy necenvalgar? F [ireauies baste custone sopra corval loc case? " Preceraty,TEAM FEASIBILITY COMMITMENT Customer: ErrS08 Date Part Number NUMBER Part Name NAME: Feasibility Considerations (Our product quaity planning team has considered the folowing questions, not intended to be all-inclusive in performing a feasiolty evaluation. The drawings and/or specffstions provided have been used as a basis for analyzing the abilty 10 meet all specified requirements. All"no” answers are supported with attached comments Identifying our concerns andior proposed changes to enable US to meet the specified requirements Dest] CONSIDERATION Fr posi adequately defines (application requienents se ena asibity evaluation? [Can the product be manufactured without incurring a = Costs for capital equioment? = Altemative manufacturing memos? fz salistical process control required on the produc? fs Silstical process control preserily used on similar producls? ere statistical process contol is used on similar products: = Are the prooesses in control ana siable? ~Are Cok's greater than 1.337 Conclusion Feesble Product can be produces as spectied with no revisions Feasibie ‘Changes recommenced (see attached), Not Feasible Design revision required to produce product within the speciied requiremerts Sign-Off ‘Team ManberTileDais ‘Team Member Me Dale Team MemberThierDate “Team Member/Tile Date Team MambariTiie/Dare Team MembariTile DalePRODUCT QUALITY PLANNING SUMMARY AND SIGN-OFF PRODUCT NAVE: custover E503 Pok- SPECIAL CHARACTERISTICS 2, SOMTEDL eLaNABEROVAL|TReHUIEs) visual LagoRAToRY =a en PROCESS MONTTORING INSTRUCTIONS PRooESe SHEETS sige one; PARTNUMBER, NUMBER, MANUBACTURING SLANT: cry SS SARRCTEETICD PER SAMS Accra EAN NEMEERTITIEDATE TERI NENSERTITLEDATE TEAN NEMEERTITIEDDATE TEAM MEMBERTTITLEDATE TEAN NEMBEATITIEDATE TEAM MEMBERTTTLEDAT: + REQUIRES PREPARATION OF AN ACTIONPLAN TO TRACK PROGRESS.PROCESS SIGN-OFF CHECKLIST TCletenents 1 rirougi 18 ‘COMPLETE AND APPROVED ALL PROCESS SIGNOFF ELEMENTS APPROVED: [Tes [No sure supniee aT tre ween a Semen oot oe arene 5) Saree Perrone a eNOS LEVEL) a Pre reo WEETING ARTE PeSevento AS «| owners PSO PROCESS ELEMENTS VERIFIED DURING PLANT VISIT PART NUMBER, DESCRIPTION AND CHANGE LEVEL ENGINEERING STANDARDS IDENT ED ‘SEGAL PRODUCT AND PROCESS CHARACTERETICS ICENTFIED PROCESS FLOW CIAGRAM AND NANUACTURING FLOOR PLAN ‘TOOLING EQUPNENT Ano GAGES DENTIAED, DESEN AUER AND PROCESS WEA, CONTROL PLAN. ‘TEST SWYPLE SZES ANDFREQUENCES GaGe AND TEST EQUPMENT EVALUBTON ERROR ANDMISTARE PROCFING PROGESS WON'T OR NG AND OPERATING INSTRUCTIONS INCOMING aNb OUTGONG MATERAL QUALIFCERT PLAN PARTS PACKAGING AND SHPANG SPECRICATIONS, PARTS HANDLING FLAN PREVENTIVE WsINTERANCE PLANS. ‘GUAUTY PLANNING. PRonua SOLNG METHCRS EVIDENCE OF PRODUCT SPEGFICATIONS LINE SPEED DEMONSTRATION "ADDITIONAL PSO PROGESS ELEWENT REQUIRED FOR "Z~ APPROVAL (ELIGIBILITY FOR PARTIAL TOOLING PAYMEN' "BOCUMENTATION PROCESS accept unsccees| acceer unscceeT 20. NITAL PROCESS STUDY Co Co};co Co ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR FULL APPROVAL 22. PRODUCTION VALOATIN TESTNG COMPLETE ARECTIVE ACTION REGURED [VES ko a neste sevisTReQuReD Les ko ‘pamercnnal: Caserton Pocsea San Taam ‘seas? ROREERT TSRRESRESESE 6 WRU REEACETAIER a SPPLEROOALT Tampons © WANUFACTURNGWINAGER TaN a TREOSUPPLIER SUPPLIER, PROGRAM Wwe Looanig® = ‘SUPPLIER COE a PART NUMBER(S) ca PARTNANE(S) Tau CaRNGELEVELS) resin PROCESS SIGN-OFF CHECKLIST COMMENTS/FOLLOW-UP SHEET FLEMENT cry ISSUE / ACTION RESPONSIBILITY SUPPLIER supper PROGRAM Nes. LocaniGW = ‘SUPrLERCOBE = aR? NUMBERS) PART NANEIS) (CARNGE LEVELS) PRE PSC Ms=TING RCE COMPLIANCE REPORT Comes With A o-Yeer Warranty. lest Urive At Ine Nearest snowroom “A minimum of 3 characteisties are be checkes. For any qven pan, assembly, or process the numberof characterises selactes cepancs pen the comply -Arminium 2¢SOrancomy slactas sanpies shallbe cneckect *Vanable data is prefers bur atribute datas acceptable *Mlirirsur vals fr Pp and Ppk shouldbe 1.7 or greater. “Foratiouie data, a30 piece sample wk one or more nonconformancoe ls unacceptable ‘SUMMARY EXAMPLE CHARACTERISTICISPEC. sawptesiz= | Ppepk | AcciuNAce Length (36-7 Simm) 30 434 TUNA Wid (12mm) 20 ane TUNACC Tle Size (2.0 7-.02mm) 20 Tan ‘ACC. CHARACTERISTICSPEC. SAVPLE SIZE | Perk | _AGGIUNAGE= Ascepiable LSL = Lower Specification Limit Pp = (USL - LSLy6S Pok = The smallerof (US =X) or OK -LSLYSS sample Standard Deviation JUNACC = Uneceepteble USL = Upper Specsteation Limit NOTE: Attach supporting detailed data and worksheets Pp. Pok> 1.67, [The diference teween Ppand Ppk should be as bar = Mean of the Sample Measurements curpuer supper PROGRAM ra, Loca = ‘SUPPLER CODE DE pares NUVEERIS) PART NAMES) (CHANGE LEVELS) =o PRE-PSO MEETING PLATE Forever Requirements And Their Impact On The Extended nterprise™ Reviewed With Supplier. Date: PRODUCTION DEMONSTRATION RESULTS Record the quantity of parts built during the Production Demonstration Run. Deviations from requirements (minimum cof two hours or 300 pieces, whichever is more stringent) must be explained ELEMENT 19 - LINE SPEED: Guaniy | Unt ot Wenswe | “eof Cap [ne Sharer _——_Yes_7_R Tr ucted DC Toot Cans umber of STs SHY ‘Other Customer Capacity” [Hours 7Shit (HR): Excess C: Daye Week OY) "Fora Tooing CapacRy Feet Operating Time Tor OC PSO Line Speed Observed arts (Hours/Day)* BUYER CONCURS WITH QUANTITIES IN ROWS 1 - 4: (Signature) Example: Goaniy [Uni ot ease | of Gap [une Stare — [ve 7 No fr Gucted DC Tooing Capasay] 1600 Piecesbay [50 [Number of Sas (STE? ‘Giher Customer Gapacty 300 Precestbay [23 [rows Sn HR) a Excess Capacity 800, Pieces/Day 25 [Days / Week (DY) 5 “Total Tooling Capac 3200 Pieves/Day 100 Net Operating Time for DC [PSO Line Speed Observed |__ 200, PiecesiDa rs oursiDay) zBUYER CONCURS WITH QUANTITES IN ROWS 1 «4 (Signature) fucked DC Tooing Capea Romar ae ‘Gther Customer Capeciy 300) Fieces/Day 35 owe San = excess Capacity 300 Fieces/Day 25 ays Week OY 5 Total Teoing Capaciy 3200, FrecesiDay |_100__INet Operating Time fer De PSO Line Spees Observes | 790 Bleces/Day 1s (HoursiDay) 7 ‘COMMENTS: ELEMENT 20 INITIAL PROCESS STUDY Characters “Guansiy | cuanity Brcass Pavormance MonitopeBe ance EMail . Guentiy Guariiy FIC Percent Operation tempted | Accepted | _evthoutRepats) i b= E- PART HISTORY Parone Patnene NUMBER NAME Date FonerPROCESS FLOW DIAGRAM PART NUMBER: NUMBER are, PART DESCAIPTIONE ect = wae PREPARED BY Pegg § 3 5 2 =| propuctano | = g 2 bE] opernoy | Z| “process |Z] contro. sree| i cescrprin | # |ousmacrensres|#| uericos OA