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opyright 2004 DAIMLERCHRYSLER CORPORATION 94I. IN-PROCESS TESTING AND FUNCTIONAL TESTING MISTAKE PROOFING
REQUIREMENTS
• All electrical connections shall have a positive detent that can be positively identified through audio, tactile or visual feedback.
• All connections shall have continuity check with automated line stop/lockout if the continuity is not achieved to verify integrity of the connection.
• All electrical components shall be verified for continuity and function. Specific care shall be taken to ensure female electrical terminal contacts are not violated or damaged prior to mating of connectors at the vehicle assembly plant. When making terminal contact for in process manufacturing (harness assembly, engine testing, device testing, etc.) the following criteria shall be followed:
o It is preferred to provide spring loaded pogo pin access to the terminals through the front of the connector.
The pogo pins shall not violate the contact area of the terminal(s) being tested.
o Pogo pins shall be properly maintained, i.e. cleaned and inspected regularly. Care shall be taken to use a
solvent/lubricant that will not damage or reduce the functionality of the terminal or contact housing.
o The test fixture shall provide features to properly align the connector to the test fixture prior to
engagement of the pogo pins.
o When pogo pin access is not provided, and spring member contact is the only option, the following
requirements shall be followed:
It is absolutely critical that the terminal spring member is not overstressed under any circumstance. The probe being used to contact the terminal spring member shall be smaller in thickness than the minimum blade (including tolerances) applicable to the terminal being tested. If round pin terminals are being tested, the male pin probe shall be smaller than the minimum diameter (including tolerances) than the applicable male pin.
The depth of insertion of the probe shall be limited to the minimum depth required to make electrical contact for testing. The contact interface of the spring member shall not be violated.
II. ELECTRO-STATIC DISCHARGE (ESD) GUIDELINES
At a minimum, the manufacturing facility should have:• ESD mats and/or floors
• Heel and/or wrist straps. ESD certified shoes are also acceptable.
• Training program for ESD (this training should be reinforced periodically)
o ESD Operators should be clearly identified (e.g. button or badge)
• ESD testers for operators – verifies heel and wrist straps, and/or shoe functionality
o ESD testers are to be included in the calibration and preventive maintenance schedules. Calibration and
preventive maintenance procedures exist to ensure the correct functionality of testers.
o Operator instructions exist for the use of these testers that include, but are not limited to, operators
testing themselves every time they enter the floor (e.g. start of shift, after lunch, if they leave the production floor for any reason).
o Log-in sheet for operators to verify all operators on the floor have been tested.
• ESD totes/bags/travelers/carts for ESD sensitive product/components to be transported to and from the line, and in-process.
• ESD workbenches that are grounded with plugs for wrist straps (if applicable).
o All workstation which are denoted as ESD stations shall have work instructions which specify any special
tools/materials required for that operation (e.g. gloves, finger cots, and heel and/or wrist straps). • ESD certification schedule
o A procedure for periodic recertification of all ESD equipment (should include how it certification is
performed, what measurements are taken, etc.).
Records of the certification and the recorded measurements shall be filed)
o All carts, workbenches, totes, travelers shall be recertified each year.
• All carts, workbenches, totes, travelers, shall be clearly identified to distinct this equipment from normal production equipment.
• ESD gloves and/or finger cots for handling of PCB's (e.g. rejects)
• An ESD support team to conduct recertification of ESD equipment each year. Also conduct informal audits to ensure operators are adhering to the established procedures. Process for Corrective Action in the event operators are not adhering to procedures or recertification is not being performed according to schedule.
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opyright 2004 DAIMLERCHRYSLER CORPORATION 95III. PRODUCTION LINE MOVE GUIDELINES
Pre-Move Activities:
1.Provide a timing schedule, by DaimlerChrysler part number, for each affected part/line. The schedule shall contain the following:
a. Start and completion ‘planned’ and ‘actual’ dates for each part/line.
b. Finished part ‘banking’ plans to provide safety net during line transfer/start-up time. Bank quantities require Buyer approval.
c. PV test timing. Test requirements are at the discretion of DaimlerChrysler Engineering and Supplier Quality.
d. Production line capability measurement timing. Process and/or product parameters and quantities to be measured will be determined by DaimlerChrysler Supplier Quality, DaimlerChrysler Engineering and the Supplier.
e. Production subassembly/subcomponent tooling capability measurement timing (if tooling is to be moved). Process and/or product parameters and quantities to be measured will be determined by DaimlerChrysler Engineering, DaimlerChrysler Supplier Quality and the Supplier.
f. Operator training timing (required if new operators are to be used).
2.Provide information on where and how the part bank will be stored (e.g. temperature controlled environment, bank location, etc.)
3.Provide a list of which PV tests will be conducted.
4.Provide a list of which production line process parameters and quantities will be measured.
5.Provide a list of which production subassembly/subcomponent tooling dimensions and quantities will be measured.
6.Provide information of how the operators will be trained. Ideally, operators will be trained on the production line prior to the line move.
7.Provide a detailed list of all tooling and equipment that is to be moved. Include tool numbers on the list. 8.Provide a list of the tool transportation method and the protective measures to prevent damage that will be
undertaken.
9.Provide updated documentation for the part being moved (process flowchart, control plan, PFMEA, etc.). 10.Provide a 2000 piece First Production Shipment Certification (FPSC) form. These quantities shall be agreed
upon by DaimlerChrysler Supplier Quality and DaimlerChrysler Engineering and the Supplier.
Post-Move Activities:
1.Report results of the production line/subassembly tooling/subcomponent tooling capability studies to DaimlerChrysler Supplier Quality and Engineering.
2.Complete PV testing and supply a copy of the completed DVP&R to DaimlerChrysler Engineering and Supplier Quality.
3.Upon successful completion of step 2 and approval from DaimlerChrysler, PPAP part per the DaimlerChrysler Forever Requirements process, then resume production.
4.Provide an updated timing schedule.
5.Complete the FPSC measurements and supply a copy of the form to DaimlerChrysler Supplier Quality and Engineering.