Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March

2008 Revision 1.0

Document #: Program: Model Year: RFQ # / Basis #: Back Office Chief / Manager Back Office Lead Program Manager Phase: ECO #: Rev: A

1444481
Template - Peel and Stick Heater Control Plan

N/A N/A Deana Borghi Joe Hebda Robert Hicks N/A

Change Description: Initial Release Date:

Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March 2008 Revision 1.0

Control Plan Form Instructions

Responsibility The Quality Manager is responsible for defining the control methods and the reaction plan, and approving and maintaining the Control Plan for the system or subsystem (i.e., Components, etc) level product manufactured at the AG plant. The Product Engineer is responsible for delivering the information about the part number and description, the product and process characteristics, the significant and critical (SC/CC), and the Design Failure Mode and Effects Analysis (DFMEA) results where they relate to the Control Plan. The Manufacturing Engineer is responsible for delivering PFMEA and the process steps and description information.

Instruction: The AQE/QE develops a Control Plan taking into consideration all requirements applicable to the system or subsystem (I.e. , Components, etc) level product manufactured at the AG plant. The AQE/QE must review the FMEA forms to identify the necessary controls. Special consideration must be given to Critical and Significant characteristics The Control Plan form has 3 distinct forms that must be completed at the required phase in the PLUS process: DV Build Control Plan: completed to support the development of prototype builds. Pre-launch Control Plan: completed after the Prototype Control Plan with the introduction of saleable vehicle builds made from production tools; used until all customer and AG requirements are met. Production Control Plan: Provided with Customer Part Submission and becomes effective upon customer approval. The above Control Plans must include/identify all known Customer Special Characteristics, AG internal Special Characteristics and Safety/Regulatory requirements (i.e., All SCs and CCs). applicable to the system or subsystem (i.e., Components, etc) level product manufactured at the AG plant. Customer SC/CCs, including those controlled at suppliers, must be addressed in the control plan. AG SC/CCs controlled in the manufacturing process must be addressed in the control plan. Note: System or subsystem level SC/CCs may be controlled at internal or external supplier/s. In this case, the AQE should complete all fields on the Control Plan up to and including the Evaluation Method field. A suggested reference in the Evaluation Method through Reaction Plan fields would be , "See Supplier Control Plan/s".

Continuous Compliance Test (CCT) requirements are reflected in the Control plan or the control plan may refer to the DVP&R for CCT requirements. Customer specific requirements, such as annual dimensional lavout, shall be identified on the Control Plan. Refer to the Control Plan Example tab in this document for examples of the above requirements. For Customer / Component BU within the scope of VDA: Note that the Control Plan shall be identified with "A" in the top right corner whenever there is at least 1 critical characteristic mentioned. This identification is required to highlight special archiving requirement (eg. 15 years) for this document. See VDA 1 brochure for details. Records / Logs The Control Plan is stored by the Quality Manager. References Advanced Product Quality Planning and Control Plan (AIAG reference manual) Characteristic Management standard (WW-PLUS-ST-02-01)
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Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March 2008 Revision 1.0

Control Plan
DV Build Control Plan Number Part Number/Latest Change Level Core Team Seat Heater team Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd) Customer Engineering Approval/Date (If Req'd) Pre-launch Production Key Contact/Phone Date (Orig.) Date (Rev.)

Supplier/Plant

Supplier Code

Other Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Part / Process Number

Process Name / Operation Description

Machine, Device, Jig, Tools For Mfg. No. Product

Characteristics Process

Special Char. Class. Product / Process Specification/Tolerance Evaluation

Methods Sample Size Freq. Control Method Reaction Plan

Measurement Technique

Operator responsibilities Stock seat heater at correct station on assembly line assure correct part number per ODS
each container

visual management

Remove incorrect product from line. Aside units handled improperly for disposition

Remove seat heater assembly from container without stress on wire harness

Use handling technique which does not stress harness, per ODS

each assembly

visual management

Post assembly, assure heater is in correct position

assure position of heater on cover meets requirements of ODS

each assembly

visual management, template

Aside assemblies positioned improperly for disposition

post assembly, assure adhesive backing tape is removed

visually check each adhesive area such that the appropriate color is showing in the tape windows

each assembly

visual check

Aside cushion assemblies which do not meet criteria

assure no foreign objects traped under heater post assembly to pad

run hand over heater to detect foreign objects

each assembly

manual check

Aside assemblies with poor adhesion to the pad for disposition

Auditor responsibilities tion, contact supervisor who mus correct operation, quarrentine all product built since last succcessful audit for verification. Stock seat heater at correct station on assembly line assure correct part number per ODS Check visually to print and ODS

Remove seat heater assembly from container without stress on wire harness

Use handling technique which does not stress harness per ODS

observe handling technique used

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once per job rotation

5 consecutive assemblies

Post assembly, assure heater is in correct position

assure position of heater on cover meets requirements of ODS within +/10 mm

scale

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Part / Process Number

Process Name / Operation Description

Machine, Device, Jig, Tools For Mfg. No. Product

Characteristics Process

Special Char. Class. Product / Process Specification/Tolerance Evaluation

Methods

Sample

once per job rotation

5 consecutive assemblies

Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March 2008 Revision 1.0

Control Method

Reaction Plan

Measurement Technique

Size

Freq.

Operator responsibilities post assembly, assure adhesive tape backing has been removed

correct color shows in tape windows

visual check

assure no foreign objects traped under heater post assembly to pad

run hand over heater to detect foreign objects

manual check

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Stop operation, contact supervisor who mus correct operation, quarrentine al built since last succcessful audit for verification.

Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March 2008 Revision 1.0

Control Plan - Example

DV Build Control Plan Number Part Number/Latest Change Level Pre-launch X Production Key Contact/Phone Date (Orig.) Date (Rev.) 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 Req'd)

Other Approval/Date (If Req'd)

Part / Process Number

Process Name / Operation Description

Machine, Device, Jig, Tools For Mfg. No.

Characteristics Product Process

Special Char. Class. Product / Process Specification/Tolerance Evaluation

Methods Sample Size Freq. Control Method Reaction Plan

Measurement Technique

A) Control at Supplier
Option 1) System/Subsystem level SC/CC Controlled at a Component/Part SC/CC Level at Multiple Suppliers Option 1a) All effected parts-see list Option 1b) All effected parts-see list Annual Supplier PPAP/Recertifcation FMVSS 201 CC Per FMVSS 201 Suppliers PPAP/Cert Review Each LF part see list Annual Annual Supplier PPAP/Recertific ation. Review PPAP. Follow Corrective Action procedure Receiving Flammability: FMVSS 302 CC Per FMVSS 302 See Supplier Control Plans See Supplier Control Plans See Supplier Control Supplier Plans Control Plans See Supplier Control Plans

Option 2) System/Subsystem level SC/CC Controlled at a Component/Part SC/CC Level at Multiple/or Single Supplier/s. This would be used a) If you choose to list all Supplier SC/CC's in the control plan b) To highlight the key SC/CC components. Option 2a) Cushion foam Part # abcdefg Option 2b) Part # 123 Annual Supplier PPAP/Recertifcation FMVSS 201 CC Per FMVSS 201 PPAP/Cert Review 1 Package Annual Annual Supplier PPAP/Recertific ation. Review PPAP. Follow Corrective Action procedure Receiving FMVSS 202 SC Foam ILD See Supplier Control Plan See Supplier Control Plan See See Supplier Supplier Control Plan Control Plan See Supplier Control Plan

(Optional) Highlight Control of a Key JCI Identified Supplier SC/CC at a Supplier (not a System/Subsystem Characteristic) This would be used to highlight a key SC/CC on components. Plastic Part # 12345 Receiving Part Length SC 30mm +/- 2mm See Supplier Control Plan See Supplier Control Plan See See Supplier Supplier Control Plan Control Plan See Supplier Control Plan

B) Control at AG Plant
Incoming Inspection Seq Number/ Etc Process # Incoming Inspection Material Specification ABC CC Must meet spec DCE Incoming Inspection 1 Cert Each Lot Review Supplier Return to Certification Supplier

Assembly Process Marriage of back to track assembly Bolt Torque Atlas Copco Torque Driver Torque Monitoring SC 24 NM +/- 4NM Torque Monitoring System Controller 100% 100% Atlas Copco Follow Corrective action plan on ODS Part not released. Following NC Material/Re work procedure Follow Corrective Action plan on ODS Follow Corrective Action procedure

Final Inspection Station 15 Set-up Shipping position Indexing Build fixture Shipping Positon SC Seat Angle 30Deg +/-5 Station 17 deg lasers 100% Continuo Automated us Inspection

Station P

Dimensional inspection Overhead System Check fixture Periodic Checks (at JCI) Dimensional inspection Overhead System Check fixture

SC1, SC2 SC3, SC4

SC

Perimeter Inspection checklist +10mm/10mm

Overhead System Check fixture

Per Shift Check Sheets

Surface Contour points A-F

SC

Perimeter Inspection checklist +10mm/10mm

CMM

Annual Layout Inspection Record

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Supplier Standards Manual Seat Heat Peel and Stick Heater Control Plan Chapter 7 Quality Section March 2008 Revision 1.0

Control Plan - Example

DV Build Control Plan Number Part Number/Latest Change Level Pre-launch X Production Key Contact/Phone Date (Orig.) Date (Rev.) 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 Req'd)

Other Approval/Date (If Req'd)

Part / Process Number

Process Name / Operation Description

Machine, Device, Jig, Tools For Mfg. No.

Characteristics Product Process

Special Char. Class. Product / Process Specification/Tolerance Evaluation

Methods Sample Size Freq. Control Method Reaction Plan

Measurement Technique

Continuous Compliance Testing - Visor Assembly Continuous Compliance Testing - Console Assembly

Flammability: FMVSS 302

CC

Per FMVSS 302

Laboratory Test

Annual Continuous Compliance Testing Annual Continuous Compliance Testing

Follow Corrective Action procedure Follow Corrective Action procedure

Flammability: FMVSS 201 and 302

CC

See DVP&R

See DVP&R

See DVP&R

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