PSO ELEMENT REQUIREMENTS
ERROR AND MISTAKE PROOFING
Element Requirements Documentation
14.1 The Error and Mistake Proofing Plan shall describe how the
Supplier addresses error proofing and mistake proofing from an organizational level.
14.1.1 The plan shall include the creation of boundary samples Boundary samples may be defined as:
• Designated conforming and non-conforming product
(e.g. Go/No Go)
• Master samples for appearance items
• Product built to the ends specification limits (i.e. just inside the spec limit and just outside the spec limit) 14.1.2 The plan shall explain how failure modes for “designated non-conforming product” are selected in the event of multiple possible failure modes.
14.1.3 The plan shall explain how the verification frequency of boundary samples is determined.
14.1.4 The plan shall describe how boundary samples are labeled.
14.2 Line or station lock out shall be implemented in the
manufacturing process at all steps to prevent failed operations (detected by mistake proofing) from proceeding to a subsequent station or into finished product. Audible and visual indicators shall notify the operator of the failed operation.
14.3 Boundary samples shall be verified on the production line as
frequently as needed to ensure mistake proofing is operational. The frequency of verification shall take into account such activities as start of shift, production changeover, major disruptions, tooling maintenance, etc.
14.4 Error and/or mistake proofing is required for severity
numbers of 9 and higher in the PFMEA and DFMEA.
• Error and
Mistake Proofing Plan
• List of error and mistake proofing implemented by operation number • Error and mistake proofing studies • Mistake Proofing Contingency Plan
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14.5 Mistake proofing is required for all special process and
product characteristics.
14.5.1 Dimensional features that affect fit, form or function
as defined by the Engineering drawings or the PSO team shall have mistake proofing to ensure that all products meet the requirements.
14.6 Rework/Repair and secondary processes shall incorporate
all error and mistake proofing from the production line.
14.7 A contingency plan shall be developed and documented in
the event the production mistake proofing is not operable. A visual and/or audible alert shall signify the mistake
proofing is inoperable.
14.7.1 In the event the mistake proofing becomes inoperable,
the DaimlerChrysler Supplier Quality Specialist shall be notified per “The Forever Requirements” for product shipment. The “Potential Non-conformance Process” shall be used when applicable.
14.8 Mistake proofing verification shall be addressed in the
Preventive Maintenance Plan.
14.8.1 Controls shall be in place to validate the on-going effectiveness of all Error and Mistake proofing. 14.8.2 Error and Mistake Proofing software shall be tested
for all possible failures, and bypass scenarios.
14.9 Mistake proofing verification shall be addressed in the
Process Layered Audit Plan and checklist.
14.10 The process shall include part presence sensing and
location assurance of all parts, at the same station or subsequent station.
Note: Mistake proofing shall verify that the final state assembly is
complete and correct. Verifying the component is in the machine prior to assembly, and then assuming it is on the finished product after the machine cycle is not acceptable.
14.11 Sequential sensing shall be used when the process utilizes
physically independent cells making up one process flow.
14.12 All assembly (secondary) equipment shall leave an
identifiable mark (physically or through software) on the part that is indicative of a successful operation (e.g. pin hole, barcode label).
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14.13 Dimensional features that affect fit and function as defined
by the PSO team, which are not capable or consistent, are to be linked to the process to ensure that all products meet requirements.
14.14 When positive alignment features cannot be designed into
the product, process alignment assists shall be implemented (e.g. laser lights, fixtures, equipment modifications, etc.).
14.15 Appropriate mistake proofing shall be implemented for the
measurement of rivet head diameter and height.
14.16 In-process verification of product performance criteria (e.g.
Cup Holder Opening and Closing Efforts, Opening Time etc) shall be applied to all functional features of the product that have a high customer interface as determined by the PSO team.
14.17 All components, which are sorted for specific application
(content or function), shall have 100% verification of proper part selection through robust mistake proofing.
14.18 All cylinders applying components or performing staking
shall be verified for full stroke.
14.19 Primary manufacturing processes (e.g. Injection Molding,
Welding, Heat staking, Machining etc.) shall have controllers (e.g. RJG, MACO etc.) with a closed loop feedback system and process limits established, to
produce a defect free product.
14.20 All critical lubrication, adhesive points, liquids and gases
shall be automated and Error and Mistake proofed for proper flow/amount/location.
14.21 Assembly machines that accommodate right and left parts
in the same process shall have mistake proofing to prevent assembly and packing errors.
Note: The process flow shall accommodate separate paths of right
and left parts if deemed necessary by the PSO team.
14.22 Supplier and sub-suppliers must comply with DCX
Supplier Quality weld validation plan for any Fusion arc weld and Resistance spot welding parts.
ERROR AND MISTAKE PROOFING (cont.)
Element Requirements Documentation
14.23 Mistake Proofing requirements for Module Assembly/ Sequenced Part Delivery (SPD)
14.23.1 Barcodes and/or pick lights shall be used to ensure the correct part is picked and assembled per the broadcast.
14.23.2 Electrical continuity testing of all the electrical components of the module, which also ensures correct content per broadcast.(See Commodity Specific – Electrical, for further mistake proofing requirements)
14.23.3 Vision systems shall ensure correct color match of components, and correct components (where applicable).
14.23.4 “Push click pull” method shall be utilized for all
electrical and other applicable connections. 14.23.5 SPD part sequence shall be maintained through the rework/repair process.
14.24 Mistake Proofing requirements for Product Testing
14.24.1 All functions, efforts and travel shall be exercised
and measured 100% on line to full extent of function and travel to ensure product
performance.
14.24.2 Leak testing for liquids and gas shall be automated and measured 100% on line.
14.24.3 The Supplier shall ensure that the number of testing and rework stations in the production process shall ensure uninterrupted flow of acceptable product to DaimlerChrysler at the quoted volume.
14.24.4 The Supplier shall ensure systematically that all reworked/repaired parts are re-verified through production testing and inspection.