YANFENG GAGE FIXTURE STARDARDS Rev006

Yanfeng Global Automotive Interiors Global Supplier Standards Manual Chapter 2 Tooling & Equipment (July 29, 2017)

Yanfeng Gage Standards

Yanfeng and Supplier Managed Gages

This manual is for the intended use of the employees and suppliers of Yanfeng, Inc. and is considered to be a PROPRIETARY DOCUMENT. Any distribution or sharing of this document is prohibited. All copies must be obtained from the Yanfeng Gage Engineer.

Uncontrolled if printed

TABLE OF CONTENTS

Introduction 2 Scope 3 General Requirements 4 Safety and Ergonomic Requirements 5 Quotation Requirements 7 Gage Design Requirements 8 A. Concept Drawing 8 B. Gage Design 8 Gage Build Requirements 10 A. Bases 10 B. Tooling Balls / Tooling Holes 10 C. Risers and Stanchions 10 D. Details 10 E. Removable Details 11 F. Hinged Details 11 G. Locating Pins 11 H. Clamps 11 I. Scribe Lines / Tolerance Bands 11 J. SPC Indicators 12 K. Build Tolerances 12 L. Labeling 13 M. Corrosion Protection 14 N. Gage Certification 14 O. Third Party Certification 14 P. Gage Instructions 15 Q. Function Check 15 R. Measurement Systems Analysis – Gage R study 15 S. Measurement Systems Analysis – Gage R &R study 16 T. Shipping / Transportation 17 U. Preventive Maintenance Instructions 17 V. Gage Records 17 W. Specialty Gaging 18 X. Automated and Semi-Automated Gaging 18 Appendices 19 A. Appendix A – Documents 19 B. Appendix B – Diagrams 40 C. Appendix C – Standard Materials List 69 D. Appendix D – Revision Table 70 E. Appendix E – Reference List 72 F. Appendix F – Glossary of Terms 73

Go to Table of Contents INTRODUCTION

TO OUR GAGE SUPPLIERS

The intent of this manual is to define the Yanfeng Global Automotive Interiors requirements for gages and fixtures. It also goes beyond the simple design and build requirements and sets forth other requirements for our Gage / Fixture Suppliers. Since Yanfeng has many customers, it is important to understand that our manual is to be used as a guide in conjunction with our customers’ standards. The intent of this standard is to supersede any customer requirements that are more lenient but to utilize any customer requirements that are more demanding. We understand that all customer requirements are different, but we believe that by using this manual, there will be less confusion and more consistency in designing and building gages for Yanfeng. The intent of this manual IS NOT to dictate the process of HOW to build a gage but to GUIDE you in completing your task.

While this manual sets forth certain minimum gage and procedural requirements, it is not intended to be absolute. It is both Yanfeng’s and the Gage Suppliers’ responsibility to continuously improve and to be objective in its approach to any gage program. Therefore, your independent analysis of these requirements and suggested changes or improvements are welcomed. We do ask, however, that any proposed deviation from this manual be approved by the Yanfeng Gage Engineer prior to its incorporation.

Your responsibility in our TEAM is a large one. The quality, functionality, value and timeliness of these gages are a direct reflection of your company. You have to not only show the expertise in your field, but also provide invaluable assets like responsiveness, integrity, dependability and ingenuity. These assets are an EXPECTATION and will not be deviated from.

Sincerely

Doug Stewart Gage Engineer Yanfeng Global Automotive Interiors

Go to Table of Contents SCOPE

This Gage Standard applies to all of Yanfeng Global Automotive Interiors - North American and its Gage Suppliers.

This Gage Standard establishes requirements for gages and fixtures that are used in conjunction with the inspection, measurement, and evaluation of the part. Such gages and fixtures are Attribute gages, SPC gages, CMM holding fixtures or any combination thereof. Generally, gages and fixtures are defined as:

FIXTURE • A device that is used to hold one or more parts while various operations are performed. For instance, a fixture is used to hold the part while an inspection is performed. GAGE • An instrument that is used to measure the part. For instance, a gage is a fixture with an Attribute rail or SPC indicator port attached to it. PLEASE NOTE: The terms fixture and gage are commonly referred to as the same piece of equipment. A fixture and a gage can be the same, but not always. If the measuring instrument is not attached to the holding device, then it is only a fixture [CMM holding fixture], whereas, if the measuring instrument is attached to the holding device [Attribute gage, SPC gage], it becomes a gage.

This Gage Standard does not establish requirements for jigs, assembly fixtures, milling fixtures, assembly nests, headliner tub fixtures, calipers, micrometers and the like. It does, however, provide instructions or guidelines that could be used with these types of equipment.

Please note the following terms and their definitions as they are used in this document:

Term Definition YF representative Yanfeng Global Automotive Interiors representative Gage Engineer Yanfeng Global Automotive Interiors Gage Engineer Supplier Gage Supplier

Go to Table of Contents GENERAL REQUIREMENTS

1. The Supplier must quote in compliance with the Reliability and Maintainability requirements as stated on the Gage Request for Quote or the form. If these requirements cannot be met, the Supplier must either “no quote” the job or obtain a written deviation from the YF representative. 2. Receipt of the hardcopy purchase order does not necessarily represent the start date of the work to be completed. The start date will be established when the purchase order number is sent via e-mail (or verbally) or the receipt of the CAD model or prints, whichever is later. The start date plus the quoted timing will establish the gage delivery date. All deviations from the delivery date must be communicated to the Yanfeng team in writing. Only circumstances fully outside of the Supplier's control will be considered as acceptable program delays. 3. All work that is started without a purchase order number and/or CAD model will be the Supplier’s responsibility, if the program is delayed or canceled. 4. The Supplier is responsible for the accuracy of all gages. Work resulting from the use of “out of calibration” equipment or defective processes will be the Supplier’s responsibility and must be corrected without cost to Yanfeng. This includes the equipment and processes for any sub-suppliers. Return to Gage Build Requirements – Section A. Gage Certification, item #1 5. If a gage was used to qualify a part or process and the it was found to be in error (i.e. built or certified with equipment that is out of calibration, a net surface is cut to the wrong side of material, etc.), the Supplier may be charged for prevailing layout cost, air freight part shipment charges, labor charges and/or other charges directly related to the discrepant gage. In addition, if a tool has been modified using a gage that was not dimensionally correct, the Supplier may be charged for the tool work to correct the part. Yanfeng will make every effort to ensure the gages are re-verified within the same parameters (temperature, humidity) as the Supplier. To ensure that equipment changes are not done hastily or needlessly, the YF representative must allow the Supplier to re-verify the gage before any changes are initiated. If there is a question or concern, the YF representative, the Supplier and the Gage Engineer will meet to resolve the issue. Return to Gage Build Requirements – Section A. Gage Certification, item #1. 6. The Supplier is responsible for part to gage clearance issues regardless of when parts are available. If the gage is shipped to Yanfeng prior to part availability, the return shipping cost will be Yanfeng responsibility. 7. All gages must be warranted against manufactures’ defects for the life of the program. Warranty items may consist of substandard materials, poor labeling or any items that may cause bodily injury. Any detail in need of repair or replacement due to operator error, poor maintenance, or overall neglect is not considered warranty items. If a warranty item is in question, it will be brought to the Gage Engineer’s attention and decided upon jointly, between the Gage Engineer, the YF representative, and the Supplier. 8. Throughout the life of the program, the Supplier may be requested to provide a cost breakdown for quoted and/or completed work. The Yanfeng Gage Cost Breakdown form must be used to supply this information. 9. No fixtures will be modified from the original design without the prior consent of the YF representative. 10. If a gage is to be used in a country other than the continental United States, all labeling and documentation must be in English and the respective native language. The Gage Request for Quote will indicate whether or not international labeling and documentation is required. The YF representative will make the final determination of which specific labels or documents are to be translated. The YF representative will assist in the translations as required. 11. If Yanfeng provides or assists in the development of new or innovative devices or techniques, the Supplier may not disclose this information (verbal or tangible) to anyone outside of Yanfeng without the written permission of the Gage Engineer. This shall prevail for a period of three years after delivery of the gage. All trade secrets and/or patent rights are the property of Yanfeng. 12. A Supplier shall not share any photograph or video images of any Yanfeng gages with anyone outside of Yanfeng without the written permission of the Gage Engineer. All images are the property of Yanfeng.

Go to Glossary of Terms

Go to Table of Contents SAFETY AND ERGONOMIC REQUIREMENTS

1. Every effort must be made to design and manufacture a gage or fixture that is operator friendly. Safety is top priority at Yanfeng and it must be carried over into the equipment that is purchased. If an ergonomic issue is in question after a fixture is built then the YF representative and Supplier must determine the course of action and financial responsibility. If agreement cannot be made the Gage Engineer will arbitrate. 2. The entire gage must be free of any sharp edges and/or burrs, paying very close attention to the “operators area of movement.” 3. Attention must be given when purchasing or designing and building toggle clamps, hinge drops, and other movable details that can pinch the operator. Clamps that are free of pinch points must be used whenever possible. 4. Toggle Clamps and hinged drops must have mechanisms installed that prevent free falling onto the operator ( handle stops , toggle clamp lockout , hinge drop lockout ). This pertains not only in its built position but also if it will be rotated into a different orientation for inspection purposes. 5. Every effort must be taken to ensure that any removable detail does not exceed 40-lbs. In those circumstances the 40-lb. weight is exceeded, assist devices such as counter balances must be used. Also, considerations must be given to the ease of removal and assembly of these details. Hand cutouts, handles, forklift sleeves or eyebolts must be installed whenever possible. 6. The following weight restrictions apply: • Fixtures < 40 pounds must have two (2) lift handles installed. • Fixtures > 40 pounds but < 65 pounds must have four (4) lift handles installed. • Fixtures > 65 pounds but < 300 pounds must have a dedicated cart or table with casters. • Fixtures > 300 pounds must have eyebolts or forklift sleeves installed. NOTE: The cart must be designed and fabricated with full and direct support on center of the fixture (center pillar with caster or leveling jack). 7. All lift handles attached to a gage should have a minimum grip length of 4”, a minimum grip width of 1”, and minimum hand access height of 1”. 8. The Supplier must make every effort to incorporate or allow for the following ergonomic information when designing and building a gage:

Operator Gage efficiency Gage design (See anthropometric chart below) (Operator motion efficiency) Arm reach Inspection tool placement Task / operation time Work envelope Proper clearances Operator postures Arm elevation Mechanisms are easily accessible Operator fatigue Work forces Mechanisms are operated easily Eliminate unnecessary motions Tools / mechanisms can be used by Motion – bending / twisting Minimize operator reaches per cycle both right and left handed people Right hand vs. left hand Working height of gage is 41” Part location on the gage

Anthropometric Measurements

Body Dimension Range of Motion Low – High

Working (standing) elbow height 38 – 47 Maximum frequent arm elevation 50 – 62 Standing eye height 57 – 70 Optimal horizontal work envelope (measured from the center of rotation of the shoulder) 12 – 15 Functional non-extended horizontal reach (measured from the shoulder blade) 25 – 32

Range of Motion figures are in inches.

9. The Supplier must make every effort to design and build the gage in a manner that is “operator friendly”. Refer to the Ergonomic Repetition Benchmark Matrix , Ergonomic Force Benchmark Matrix , and the Ergonomic Posture Benchmark Matrix for further clarification. The Supplier may contact the Yanfeng Ergonomics team for clarification.

Go to Glossary of Terms

Go to Table of Contents QUOTATION REQUIREMENTS

1. Each gage quotation must contain the following information: • Yanfeng program name • Part description • Detailed description of the work to be accomplished. • Any deviations from the quotation. • Itemized cost – Design – Build – Third Party Certification** – Gage R • Quotation total cost • Itemized timing – Design – Build (NOTE: Timing for internal Certification, Third Party Certification and Gage R must be included in the gage build timing.)

** See Gage Build Requirements – Section B. Third Party Certification, Item #1 for Third Party Certification requirements. 2. The Supplier’s quote must reflect the use of the materials listed in the Standard Materials list. Reference Appendix C. Standard Material List . 3. If a Supplier intends to use recycled components on the gage, it must be identified on the quote. If it is not noted, the gage must be built using new components. 4. It is important that the Supplier understands the specific quote requirements at the time of quotation. Cost and timing must reflect these requirements. Further, any assumptions and/or exceptions that affect cost and timing must be clearly identified on the quotation. 5. When a quotation requires flush and feeler details, sheet metal representations, or part surface representations, aluminum or fixture plank must be used. Overall gage weight and/or detail wear resistance are items to consider when determining which material to use. 6. If a part requires CMM dimensional inspection on the underside of the part, then the part must be held a minimum of nine (9) inches off the base , otherwise it may be held as close to the base as feasibly possible. Return to Gage Design Requirements – Gage Design, Item #9 7. The gage base size must be a minimum of four (4) inches larger on each side than the size of the part as held on the gage. The base type, MIC 6 tooling plate verses cast aluminum, will be determined by the gage size. For parts that require bases bigger than 400 in², a cast aluminum base will be required (a welded steel base may be used with the approval of the YF representative). All other parts will require a MIC 6 tooling plate base. MIC 6 tooling plate bases must be a minimum of one (1) inch thick. In some cases, due to part configuration and/or fixturing requirements, a cast aluminum base smaller than 400 in² may be required. It is the Supplier’s responsibility to ensure that the proper base size and type will be used. If the base is in question, the Supplier must contact the Gage Engineer or YF representative for clarification. Return to Gage Build Requirements – Section A. Bases, item #4 8. If a Supplier chooses to “no quote” a gage or gage program, a 24-hour (or less) response time is required. This includes refusal of a package that is sourced using the Gage Assumptions / Gage Cost Model form. 9. Yanfeng may use the Gage Assumptions / Gage Cost Model form to estimate and source plastic part gages. When this form is used, the Supplier is not required to provide a quote, unless directed by the YF representative. If a cost breakdown is required, the Supplier will breakdown the Gage Cost Model cost vs. the supplier’s quoted cost. The Gage Cost Model will not be used to estimate costs of engineering changes.

Go to Glossary of Terms

Go to Table of Contents GAGE DESIGN REQUIREMENTS

A. CONCEPT DRAWING

NOTE: The concept drawing/design will be required on an “as needed” basis as dictated by the YF representative.

1. The Concept drawing is to be drawn on an 8.5" x 11" sheet of paper. 2. The Concept drawing must show the “Gage Intent.” It should reflect the Geometric Dimensioning and Tolerancing (GDT) scheme and any special requirements reviewed at the quotation meeting. It should show approximate base size, part orientation, location of datums, location and orientation of clamps, location of flush rails / feeler rails, and location of SPC ports. The concept must be labeled with the Yanfeng gage number and gage description. 3. The concept review and approval DOES NOT give the authority to order gage materials. As shown in the Gage Design Requirements – Section B. Gage Design, item #11 , approval of the gage design authorizes the ordering of materials and components. If gage materials have been ordered prior to final design approval, and changes are made to the gage design that affect these materials, the material costs for the unusable stock will be absorbed by the Supplier.

Go to Table of Contents B. GAGE DESIGN

1. All gage designs produced for Yanfeng must be computer generated. All designs must be in IGES format, both wire frame and surface data included. Whenever possible, the fixture must be designed using solid modeling software for proper interpretations during design signoffs. 2. The gage design is intended to be an accurate representation of the gage. It should reflect how the gage will be constructed and must include the basic information such as, base size and type, part orientation, location, size and orientation of all stanchions, details and clamps, size and location of datums, location of flush rails / feeler rails, and location of SPC ports. It must have all necessary section cuts to show detail and any required blow up sections. Also, all internally manufactured “one-of-a-kind” components need to be drawn and dimensioned on the design. 3. Datums that are located on or near parting lines, gates, ejector pins, welds or any similar features must be brought to the attention of the YF representative for correction. 4. All stock items should be commercially purchased whenever possible. 5. All designs must have an isometric view of the gage on the design. 6. All designs must list all parts (assemblies, subassemblies or versions) that can be verified on the gage. Part numbers that are referenced must be the less finish part number(s) without color designation. 7. All designs will be drawn and dimensioned using the metric system (except Standard English stock sizes) unless otherwise specified by the YF representative. 8. Each design must have three Tooling balls or two Tooling holes and a Surface Target with start coordinates labeled on the gage base. If a gage is to be sub-based, these items must be on each base. 9. All datum surfaces and locators must be labeled on the design with the respective GDT datum callout. 10. When a slot or similar feature is used as a Regardless of Feature Size (RFS) 4-way locator, it must be so designed as to allow each locating feature to move independently. 11. All Pins and Blocks used for part inspection (i.e. go/nogo pin, plug gage, virtual condition pin) must be labeled on the design with their respective size as well as the calculation(s) used to obtain that size. 12. If the design reflects a coordinate system other than the automotive X, Y, Z system, then the design must be clearly identified with the appropriate coordinate references (i.e. H, W, L). 13. If the part is to be positioned in a different coordinate system than the CAD model (tool die draw or workline verses body position), the design must be labeled in a distinct manner with the appropriate rotation points and angles to move to and from the original system. Return to Gage Build Requirements – Section K. Labeling, item #3 14. The design must show the storage locations for removable details or interchangeable details , and loose components (SPC Indicator, GO-NOGO pins, Plug gages) . Also, when loose details or components are needed, a general note for tethering of the details is required to be on the design. Return to Gage Build Requirements – Section E. Removable Details, item #1 15. The design must reflect the proper clearance for dimensional layout inspection. Reference Quotation Requirements – Item # 4 . 16. The YF representative must approve the initial gage design and subsequent design changes. It is recommended that two reviews take place – one at or about 50% completion and one at 100% completion. The design does not have to be signed at the 50% review, but must be for the 100% review. The YF representative and the Supplier must sign the final design. Other signatures may be required, as dictated by the customer design standards and/or the YF representative. It is the Supplier’s responsibility to notify the YF representative prior to completing the design to determine who is required to sign the final design.

17. Design approval gives the authority for the Supplier to order gage materials. If materials have been ordered prior to final design approval and changes are made to the gage design that affect these materials, the material costs for the unusable stock will be absorbed by the Supplier. Return to Gage Design Requirements – Section A. Concept Drawing, item #3 18. All design changes must be recorded in a standard change column on the design. 19. All gage details must be confined within the boundaries of the base , including details that move (toggle clamps, hinge drops, etc.) 20. The approved (signed) design is the property of Yanfeng and will be stored at the Supplier. An electronic copy (and hard copy as required by the YF representative) must be supplied with the gage each time the design is updated. Reference Gage Build Requirements – Section H. Records, Item #2 . 21. Yanfeng will supply all CAD models in its native format (CATIA, UNIGRAPHICS, etc.). Every effort will be made to minimize the file size while ensuring all the critical data is supplied. All IGES translation errors or problems are the Supplier’s responsibility. 22. In the event that the customer requires a manual design, items 2 – 14 above and standard gage design practices apply. The original design must be drawn on Mylar and must be neat and legible. 23. Consideration for maximum CMM access must be given when designing the clamp type and location. Horizontal handle or bayonet type clamps should be used when CMM access is a priority.

Go to Glossary of Terms

Go to Table of Contents GAGE BUILD REQUIREMENTS

A. BASES

1. It is the Supplier’s responsibility to ensure that the base meets the flatness, parallelism and squareness tolerances as specified below. The datum scheme for these base measurements is defined as the base bottom as it sits in the horizontal position.

º 0.10 A Per 300 mm 2 º 0.20 A Not to exceed over entire base

· 0.10 A Between top and bottom surfaces

Ô 0.15 All machined edges

NOTE : All Tolerances specified are in millimeters. 2. All edges must be machined square and beveled. 3. The base must have the J-Corner identified . 4. All Tooling plate bases smaller than 200 in 2 require four (4) jig feet , one at each corner. Bases between 200 in 2 and 400 in 2 require five (5) jig feet , one at each corner and one in the center. Bases larger than 400 in 2 a cast aluminum base is required. A welded steel base may be used with the approval of the YF representative. Reference Quotation Requirements – Item # 5 . 5. Tooling plate bases must be a minimum of 1” thick. 6. Cast aluminum, welded aluminum or steel bases must be stress relieved. 7. All bases must be of uniform thickness . It is the Supplier’s responsibility to inspect the base for uniformity before construction. If the gage is constructed and the base is found to be varying in thickness, the base will have to be replaced and reconstructed at the expense of the Supplier.

Go to Table of Contents B. TOOLING BALLS / TOOLING HOLES

1. Three (3) Tooling balls or Tooling holes must be located and identified with the start coordinates on the base of the gage. These features will be used to establish the origin of the fixture for certification and part layout. Reference Gage Build Requirements – Section D. Details, Item #11 , for tooling ball requirements as single point net representations (datum target). 2. Tooling ball size will be .500 inch. Tooling hole size will be a minimum of 10 millimeters. 3. Each Tooling ball must have a protective cover. The cover must not interfere with the start coordinate labels.

Go to Table of Contents C. RISERS and STANCHIONS

1. The risers and stanchions must be attached to the base securely with a minimum of two (2) dowels and two (2) cap screws unless specified in the design as a removable detail. Reference Gage Build Requirements – Section E. Removable Details . 2. Risers and stanchions may be relieved or cut away in certain areas to gain access to the part for dimensional inspection. It is the Supplier’s responsibility to ensure the area(s) that are removed do not affect the integrity or stability of the gage.

Go to Table of Contents D. DETAILS

1. All details must be attached to the base securely with dowels and cap screws. It is the Supplier’s responsibility to ensure that the correct quantities of dowel and cap screws are used. If the quantity is substandard, the Supplier must fix or replace the detail without costs to Yanfeng. Reference GAGE BUILD REQUIREMENTS – Section E. Removable Details for details that are to be built as removable. 2. Details shall not be shimmed during construction. 3. Details used as net surfaces must be made of steel. Steel plates located on aluminum details may be used. 4. Flush rails, feeler rails and sheet metal representations must be constructed of aluminum or fixture plank. Fixture plank must be sectioned into details no larger than 400 mm in length each. 5. A 6 mm gap distance is to be used, unless otherwise specified by the YF representative customer gage build standards. 6. All net details that net around the area of a hole or cutout in the part must have CMM probe clearances cut into the detail. These clearances must be a minimum of five (5) mm deep and two (2) mm bigger than the part feature. 7. All loose details (Plug gages, Go/NoGo pins) must be tethered to the gage using chain, Car-Lane cable, or retractable spring-loaded 10

cases with cable lockouts. These chains or cables may be removed if the detail is to be used when the part is scanned. 8. All noncircular plug gages must be keyed for orientation. 9. Unless otherwise specified by the customer, a plug gage located in a bushing and clamped on top will be the method to represent a screw or fastener pin . 10. When a single point datum target is required, a tooling ball must be used. The associated clamp must be adjusted to not deform the part. Return to Gage Build Requirements – Section B. Tooling Balls – Item #1 11. Each feeler rail must have an associated go/nogo feeler pin that reflects the proper tolerance.

Go to Table of Contents E. REMOVABLE DETAILS

1. All removable details must use hardened bushings and bullet nose dowels . The bushings must be in the detail and the dowels must be in the mating component. Reference Design Requirements – Section B. Gage Design, item #14 . 2. When there are similar removable details used on the same gage, the details must have a unique locating scheme for each. Each detail and storage location must be clearly labeled or color-coded. Reference Gage Build Requirements – Section C. Risers and Stanchions – Item #1 Reference Gage Build Requirements – Section D. Details – Item #1

Go to Table of Contents F. HINGED DETAILS

1. All hinge drop details must be counterbalanced or have a lock out mechanism installed. This also pertains if the gage will be tipped 90° to inspect the part. 2. All hinge drop details must have rubber stops installed to prevent damage.

Go to Table of Contents G. LOCATING PINS

1. All locating pins must be tapered and spring-loaded (RFS pin). The Gage Engineer or YF representative must approve all other pins (MMC pin, LMC pin). 2. All tapered RFS pins must locate the part approximately at the mid point of the taper. 3. All locating pins must be made of hardened steel. 4. If a locating pin must be locked out to load the part, the lockout mechanism must be positive. For instance, if a detail has an “L” shaped cut to lockout the locating pin, the cut must have enough lead in to disengage the locating pin and hold it out of position. 5. The locating pin spring pressure must be strong enough to locate the part without distortion when clamped. 6. Spring loaded locating pins must move freely in all directions except the locating direction using graphite lubricant.

Go to Table of Contents H. CLAMPS

1. All clamps must have a clamp direction of 90° to the part surface. 2. Clamps that are spring loaded must have a positive lockout mechanism . 3. When clamping over a hole, the clamp foot must be cut to allow access to the hole. 4. When engaging a clamp, it must not interfere with the part or any other detail(s) on the gage. 5. Clamp pressure must be the minimum required to locate the part, but stronger than the opposing spring-loaded features. 6. All clamp pressure feet must be mar-proof. Examples are rubber, neoprene or nylon. If metal clamp feet are required, they must be free of burrs and sharp edges and have a mar-proof coating.

Go to Table of Contents I. SCRIBE LINES / TOLERANCE BANDS

1. All scribe lines and tolerance bands must be scribed or milled into the surface. Painted lines on the surface are not acceptable. 2. All scribe lines and tolerance bands must be identified with a distinct color to ensure good visibility for measurement. If a nominal line is included in the tolerance band, the nominal line must be contrasting color within the tolerance band. 3. Every effort must be made to minimize or eliminate the effect of the parallax error. 4. As required by the Customer or YF representative, gage bases may have bodylines scribed on them. It is recommended that the bodylines are scribed every 100 mm for smaller fixtures and 200 mm for larger fixtures. These bodylines must be labeled with the appropriate body coordinate and left hand (-) or right hand (+) signification. 11

Go to Table of Contents J. SPC INDICATORS

1. The SPC indicator type to be used on all gages supplied to Yanfeng will be Mitutoyo series 543 or 575. Specific indicator features (resolution, discrimination, travel, and sensitivity) will be dictated by each application. 2. Master set blocks will be at a length of 31mm and 50mm for applications that require more CMM access. 3. All indicators must be set up to zero out in the approximate center of its travel length. For instance, if an indicator has a 1-inch travel, the indicator must be zeroed out at .5 inch. 4. The SPC indicator bushing and port sizes will be 3/8” I.D. and O.D. respectively. 5. The check direction of each indicator must be 90º to the surface it is measuring. 6. The proper indicator tip must be used for each application. Examples are listed below: • Ball point / spherical / conical tip – used to check a point on a compound surface or overall length indicating on a Micro slide. • Flat tip – used to check a part edge that has a radius at the checkpoint. • Knife blade (chisel) tip – used to check a part edge with a flat contour. 7. Indicator extensions should be used sparingly or only as the application dictates. Extensions must be kept to the shortest length possible to obtain an accurate measurement. 8. All indicator extensions and tips must be tightened without using lock-tite or other chemical fasteners. 9. A feather-light indicator must be used if the inspection point on the part is flexible or touch sensitive. 10. All indicators must have a minimum metric discrimination of three (3) decimal places (.001 mm). 11. All indicators must have a dimensional certification, from the manufacturer, when shipped from the gage supplier. 12. All indicator collars must be placed within +/- 1.0 mm of the indicator’s center of travel. 13. All indicators must be identified with the gage supplier’s job number & SPC identification: NON-SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 1 SPC port on gage 1234-1 2 (or more) SPC ports on gage 1234-1/2/3/… SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 1 SPC port for each hand on gage 1234LR-1 2 (or more) SPC ports for each hand on gage 1234LR-1/2/3/…

Go to Table of Contents K. BUILD TOLERANCES

NOTE: • Tolerances are established using the following gage certification datum scheme - the primary datum is the surface plane established by the tooling balls or tooling holes, the secondary datum is the longer line established by the tooling balls or tooling holes and the tertiary datum is the shorter line established by a single tooling ball or surface target. • The check direction is defined as the direction(s) in which the part is to be held. • The non-check direction is defined as the direction(s) that the part is not to be held. • All tolerances are in millimeters unless otherwise noted. 1. Net Surfaces 0.20 A B C Check direction 1.00 A B C Non-check direction 2. Round Pin Locators (4-way / 2-way) 0.10 A B C Check direction Ø Ø 0.50 A B C Non-check direction 3. 2-way on slide (pinned at center & pinned at one end) 0.10 A B C Pinned at center of travel Ø 0.10 A B C Pinned at end of travel (checked ¼to slide travel) 12

4. All other Locators 0.10 A B C Check direction 0.50 A B C Non-check direction 5. Attribute rail – flush and/or feeler [vector check] 0.40 A B C 6. Attribute rail – flush and/or feeler [shank check] 0.40 A B C

7. Sheet metal representation 0.30 A B C 8. SPC port location Ø 0.20 A B C Check direction

Ø 0.50 A B C Non-check direction 9. Scribe lines 0.60 A B C 10. Sight checks (painted) 1.00 A B C 11. Slides 0.10 A B C Entire travel 12. Check pin location (MMC, LMC or VC pin)

Ø 0.15 A B C Check direction 13. Go Pin size +0.00 / -0.02

14. Nogo Pin size +0.02 / -0.00

Go to Table of Contents L. LABELING

1. All labeling on the gage must be legible and descriptive. The labeling must be placed in such a manner that it is readable when the part is on the fixture. Labels may be engraved, printed or stamped. If tags are used, they must be permanently attached to the gage. 2. The following detail types must be labeled on the gage: • All datums (net surfaces and locators) • Clamp sequence • Flush rail location and offset measurement • Feeler rail location and offset measurement • Go/NoGo pin sizes • Indicator port reference number • Master set block offset measurement • Body line references (appropriate customer references – XYZ or LWH) • Specific measurement locations 3. Tooling balls or tooling holes on the base must be clearly labeled with their respective start coordinates . If there are more than three (3) tooling balls or tooling holes on the base, the three (3) that are used to certify the fixture must be labeled with the word “Origin” next to the coordinate. Coordinates will be assumed to be in body position, but if they are in work line or other, they must be clearly identified with the coordinate system used. Reference Gage Design Requirements, Section B. Gage Design, item #7 . 4. Each gage must have a Supplier Identification tag permanently attached to it. Each tag must be labeled with the following information: 13

A. Supplier name, address and phone number B. Supplier job number C. Customer D. Yanfeng Gage Number (84xxxx) E. Gage Description F. Part Revision Level G. Certification date H. Program name(s) and part name(s) As Required I. Third party source name, address, phone number and certification date J. List of part numbers and names (if gage checks multiple parts) 5. Gage instructions must be affixed to each gage. Reference Gage Build Requirements - Section P. Gage Instructions, item #2 . 6. All indicators must be identified with the gage supplier’s job number & SPC identification: NON-SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 1 SPC port on gage 1234-1 2 (or more) SPC ports on gage 1234-1/2/3/… SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 1 SPC port for each hand on gage 1234LR-1 2 (or more) SPC ports for each hand on gage 1234LR-1/2/3/…

Go to Table of Contents M. CORROSION PROTECTION

1. All steel components must be black oxided. 2. All non-mating surfaces must be painted with the customer-required color. If a color is not specified, blue is to be used.

Go to Table of Contents N. GAGE CERTIFICATION

1. It is the Supplier’s responsibility to ensure that the cutter path and certification data are correct. See General Requirements – item #4 & General Requirements – item #5 for clarification. The accuracy of the gage must be verified using a certified CMM (traceable to a national standard). One of a kind details, like step blocks or thickness feelers, may be certified with traceable hand held equipment (micrometers, calipers). Purchased inspection details and devices (gage pins, scales, indicators) may be certified by including the certification report from the manufacturer. If a report is not sent, the detail must be certified using appropriate means. 2. The Supplier Internal Certification must use a vector check for all net surfaces, sheet metal representations and compound surfaces. A “set two, check one” check may be used on details that represent a one-direction check like a net point, flush rail, or feeler rail. SPC bushing locations must be verified and reported in the check direction but only verified in the non-check direction. Pin size and location and hole size and location must be verified and reported. 3. The number of certification masters developed for each detail is dependent on the size and complexity of the detail. It is the Supplier’s responsibility to develop a sufficient amount of points to demonstrate that the gage is dimensionally correct. As an example, on a typical 25 mm x 25 mm net block, it is recommended that a minimum of five (5) masters be used. There must be enough masters to evaluate any single or combination of elements of size, location, orientation and profile. 4. All gage certifications must include a “road map” of the certification points. 5. All two way locators on a slide , must be certified in the center and at one end of the slide’s full travel. Each location must be pinned (for certification) and clearly identified on the gage certification.

Go to Table of Contents O. THIRD PARTY CERTIFICATION

1. A Third Party Certification is required on all gages that are manufactured by a Supplier who’s certification department IS NOT accredited to a nationally recognized laboratory or inspection standard (i.e. ISO Guide 25 or ISO Guide 17025). This accreditation must be performed by a duly recognized accreditation body (American Association for Laboratory Accreditation – A2LA or equivalent). Certification to the QS9000 or TE9000 standard DOES NOT supersede this requirement; it is in conjunction with it. Refer to the AIAG QS9000 manual paragraph 4.11.2.b.1 for clarification. This Third Party certification must be performed one of two ways: • The third party source verifies the certification masters against the CAD model and inspects the gage at the third party facility. • The third party source develops new certification masters and inspects the gage at the third party facility. 14

Return to Quotation Requirements – item #1 2. It is the Supplier’s responsibility to ensure the accuracy and on time delivery of the Third Party Certification. 3. If the Third Party Certification is found to be discrepant, it is the Supplier’s responsibility to correct it without cost to Yanfeng, up to and including the internal and Third Party recertification.

Go to Table of Contents P. GAGE INSTRUCTIONS

1. All gages must have gage instructions attached to the gage. Also, an electronic copy must be supplied on a CD upon delivery of the gage. Reference Gage Build Requirements – Section H. - Gage Records, item #2 . 2. The gage instructions must be detailed and understandable with references to the gage clearly labeled. They must identify the gage preparation, loading, clamping, inspection and unloading of the part. The instructions must include all part configurations. They must include a picture of the gage with the appropriate references identified (locators, net surfaces, check points, etc). Return to Gage Build Requirements – Section K. – Labeling, Item #5

Go to Table of Contents Q. FUNCTION CHECK

1. A function check must be performed prior to delivery of the gage. The Supplier may utilize their own completion checklist, but it must include all the items listed on the gage completion checklist in the appendix. The function check of the gages must consist of the following steps as a minimum: A. Evaluate the gage against the gage design. B. Function all components on the gage. C. Using the gage instructions, load the part on the gage. D. Identify and remove all interferences. E. Document the results. F. Correct any discrepancies. 2. It is the Supplier’s responsibility to request parts for the function check. If the gage is to be delivered prior to part availability, all items above must be performed, with the exception of items C and D. When parts become available, it is the responsibility of the Supplier to complete the function check.

Go to Table of Contents R. MEASUREMENT SYSTEMS ANALYSIS – Gage R study

1. A Gage Repeatability (Gage R) study must be performed prior to final buyoff and/or delivery of the gage. For engineering changes, refer to step #6. 2. The inspection points for the Gage R study must be approved by the Yanfeng Gage Engineer or YF representative prior to completing the study. 3. The Gage R studies must conform to the following: CMM Holding Fixture or Attribute Gage a. A set of nine (9) Gage R studies must be performed on the CMM; three (3) studies for each set of three (3) points in each body direction – 3 pts FA, 3 pts CC, and 3 pts FA. CMM/SPC Gage a. A set of nine (9) Gage R studies must be performed on the CMM; three (3) studies for each set of three (3) points in each body direction – 3 pts FA, 3 pts CC, and 3 pts FA. b. Each SPC “point on part” coordinate must be performed on the CMM. c. Each SPC port must have a study performed by manually inserting the indicator into the port. Phase 1 / Phase 2 Design and Build Gage a. For Phase 1, follow CMM Holding Fixture, item a. b. For Phase 2, follow CMM/SPC Gage, items b & c.

4. The Gage R study will use one (1) operator loading one (1) part ten (10) times. 4.1. The Gage R studies must be performed using the CMM as well as manually inserting the indicator(s) into the SPC port(s) as identified in item 4. 4.1.1. CMM HOLDING FIXTURE or ATTIBUTE GAGE A. Obtain one (1) part from the Yanfeng representative. B. Using the CAD model, obtain nine (9) body coordinate points, three in each direction (X, Y, and Z) to show the most variation in each axis. NOTE: The chosen points must be approved by the Yanfeng Gage Engineer or representative. It is preferred that each point be on an edge to allow the CMM to “shank” check the part, checking only in the primary check direction. C. Using the gage instructions, load the part on the gage. D. Using a CMM, measure each of the body coordinates. Record the deviation from the master check direction for each 15

coordinate. E. Unload the part. F. Repeat steps C–E until the ten (10) trials are complete. G. Input data into the Gage R form, calculate and analyze the result (MiniTab Type 1 Gage Study is the preferred method). H. If the study is found to be unacceptable, the Yanfeng Gage Engineer and/or representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result. 4.1.2. SPC GAGE A. Obtain one (1) part from the Yanfeng representative. B. Using the gage instructions, load the part on the gage. C. Zero indicator in Master Block. D. Insert indicator into each SPC port and record the measurement(s). E. Unload the part. F. Repeat until all readings, at each SPC location, have been obtained. G. Input data into Gage R form, calculate and analyze the result (MiniTab Type 1 Gage Study is the preferred method). H. If study is found to be unacceptable, the Yanfeng Gage Engineer and/or representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result. 4.2. Acceptance criteria for the Gage R / Type I gage study will be as follows: >20% Will not be accepted without approval from the YANFENG representative.

Borderline acceptable. Must investigate cost and timing impact to improve 10% - 20% measurement system. Yanfeng representative must approve plan.

0% - 10% Acceptable.

5. The Attribute study will be performed using the CMM Fixture method. Refer to item 3 and 4.1.1. 6. If an engineering change is completed that affects the locating or measurement scheme of the gage, the Measurement Systems Analysis process must be re-verified. If the engineering change is in question, it is the Suppliers’ responsibility to contact the Yanfeng representative for clarification. 7. Completion of the Gage R&R study does not waive the Supplier’s responsibility to repair or adjust the gage (at no cost to Yanfeng) if the Gage R&R study or Attribute study, required for PPAP, is unacceptable. The Yanfeng representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result.

Go to Table of Contents S. MEASUREMENT SYSTEMS ANALYSIS – Gage R&R study 1. A Gage Repeatability and Reproducibility (Gage R&R) study must be performed prior to final buyoff and/or delivery of the gage. For engineering changes, refer to step #7. 2. Yanfeng will supply a minimum of one (1) operator for this study. The Gage Supplier must obtain approval prior to running the study without YF representation. 3. The inspection points for the Gage R&R study must be approved by the Yanfeng Gage Engineer or YF representative prior to completing the study. It is preferred to use the same points from the Gage R study. 4. The Gage R&R studies must conform to the following: CMM Holding Fixture or Attribute Gage b. A set of nine (9) Gage R studies must be performed on the CMM; three (3) studies for each set of three (3) points in each body direction – 3 pts FA, 3 pts CC, and 3 pts FA.

CMM/SPC Gage a. A set of nine (9) Gage R&R studies must be performed on the CMM; three (3) studies for each set of three (3) points in each body direction – 3 pts FA, 3 pts CC, and 3 pts FA. b. Each SPC “point on part” coordinate must be performed on the CMM. c. Each SPC port must have a study performed by manually inserting the indicator into the port. Phase 1 / Phase 2 Design and Build Gage a. For Phase 1, follow CMM Holding Fixture, item a. b. For Phase 2, follow CMM/SPC Gage, items b & c. 5. The Gage R&R study will use three (3) operators loading ten (10) parts three (3) times each. 5.1. The Gage R&R studies must be performed using the CMM as well as manually inserting the indicator(s) onto the SPC port(s) as identified in item 4. 5.1.1. CMM HOLDING FIXTURE or ATTRIBUTE GAGE I. Obtain ten (10) parts from the Yanfeng representative. J. Using the CAD model, obtain nine (9) body coordinate points, three in each direction (X, Y, and Z) to show the most variation in each axis. NOTE: The chosen points must be approved by the Yanfeng Gage Engineer or representative. It is preferred that each point be on an edge to allow the CMM to “shank” check the part, checking only in the primary check direction. 16

K. Using the gage instructions, load the part on the gage. L. Using a CMM, measure each of the body coordinates. Record the deviation from the master check direction for each coordinate. M. Unload the part. N. Repeat steps C–E until the ten (10) trials are complete. O. Input data into the Gage R&R form, calculate and analyze the result (MiniTab Type 2 Gage Study is the preferred method). P. If the study is found to be unacceptable, the Yanfeng Gage Engineer and/or representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result. 5.1.2. SPC GAGE I. Obtain ten (10) parts from the Yanfeng representative. J. Using the gage instructions, load the part on the gage. K. Zero indicator in Master Block. L. Insert indicator into each SPC port and record the measurement(s). M. Unload the part. N. Repeat until all the readings, at each SPC location, have been obtained. O. Input data into Gage R form, calculate and analyze the result (MiniTab Type 2 Gage Study is the preferred method). P. If study is found to be unacceptable, the Yanfeng Gage Engineer and/or representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result. 5.2. Acceptance criteria for the Gage R / Type I gage study will be as follows: >20% Will not be accepted without approval from the YANFENG representative.

Borderline acceptable. Must investigate cost and timing impact to improve 10% - 20% measurement system. Yanfeng representative must approve plan.

0% - 10% Acceptable.

6. The Attribute study will be performed using the CMM Fixture method. Refer to item 4 and 5.1.1. 7. If an engineering change is completed that affects the locating or measurement scheme of the gage, the Measurement Systems Analysis process must be re-verified. If the engineering change is in question, it is the Suppliers’ responsibility to contact the Yanfeng representative for clarification. 8. Completion of the Gage R&R study does not waive the Supplier’s responsibility to repair or adjust the gage (at no cost to Yanfeng) if the Gage R&R study or Attribute study, required for PPAP, is unacceptable. The Yanfeng representative and the Supplier must jointly determine the improvements needed to obtain an acceptable result.

Go to Table of Contents T. SHIPPING / TRANSPORTATION

1. All gages must be completely protected from the elements when being shipped. 2. All gages must be secured when shipped. 3. Yanfeng will accept full responsibility of the gage when it is delivered and unloaded at Yanfeng receiving location.

Go to Table of Contents U. PREVENTIVE MAINTENANCE INSTRUCTIONS

1. All gages must have Preventive Maintenance instructions supplied electronically on the CD upon delivery. 2. The Preventive Maintenance instructions must be detailed and understandable with references to the gage clearly labeled. They must identify the maintenance instructions, recommended frequency of maintenance, recommended chemicals / solutions to use for maintenance and long-term storage preparation instructions. NOTE: If the chemicals / solutions cannot be purchased “over the counter”, then a hardcopy of the MSDS sheet must be included with the gage upon delivery.

Go to Table of Contents V. RECORDS

1. The Supplier is responsible to provide an itemized Gage Timing chart for each gage from initial kickoff to delivery on a periodic basis. The report will be due every week but may be modified by the YF representative. Delays in program timing must be reported immediately, first verbally, then on the hardcopy timeline. For gages with total timing of less than three (3) weeks, no timeline is required. 2. The Supplier is responsible to provide two (2) electronic copies of the latest documents and data on a Compact Disk each time the gage is modified*. One copy will be attached to the gage and the other will be delivered to the YF representative. This disk must contain the following: • Native CAD model 17

• Gage Design • Gage Certification • Gage R and/or Attribute study or studies • Gage Instructions • Gage Preventive Maintenance Instructions • Digital picture of the gage • Any other pertinent documents as required • Final gage timeline - OPTIONAL • Final gage checklist - OPTIONAL ∗ Modified is defined as any change to the fixture or its documents due to a Yanfeng or OEM directed change, repair, correction, etc. All modifications do NOT necessarily constitute a YF representative level change. Return to Gage Design Requirements – Section B. Gage Design, Item #21 Return to Gage Build Requirements – Section C. Gage Instructions, Item #2 3. The CD jacket must be labeled with the Supplier name, Supplier job number, Yanfeng Tool Number, Gage Description, and revision level. 4. All documents that require signed approval will be in original hard copy format and kept at the Supplier.

Go to Table of Contents W. SPECIALTY GAGING

NOTE: Specialty Gaging is defined as any fixture or gage that employs the use of non-contact or technologically advanced devices used in place of more commonly used analog devices. Examples may include Lasers probes, Vision systems, or Magnetic systems.

1. The Supplier is responsible to prove-out and validate Specialty Gaging using the same methods as a fixture or gage as defined in this standard. In addition, the Supplier is responsible to verify all software applications and/or written code provided with the gage. This verification is to be performed by testing the input and output relationships and results with a minimum of 3 replications on 10 different parts. This verification study must be documented and supplied with the gage. 2. Specialty gages must meet the YF Special Equipment General Specifications (SEGS) and Special Equipment Safety Specifications (SESS) as well as any applicable industry standards that may not be covered in the SESS and SEGS documents. If aspects of these manuals are in question, contact the YF representative or Capital Equipment Buyer for clarification.

Go to Table of Contents X. AUTOMATED and SEMI-AUTOMATED GAGING

NOTE: Automated Gaging is defined as piece of equipment that is used to assess the acceptability of the part without operator intervention, except for loading and unloading of the part. Semi-Automated Gaging is defined as a piece of equipment that is used to assist the operator in loading, clamping, measurement and/or unloading of the part. Examples for both types of gages may include pneumatic equipment or electronic equipment.

1. Prior to design and build of any Automated Gaging, the YF Representative must complete an Equipment Specification sheet. This sheet will be used in place of the Gage Request for Quote or Gage Assumptions / Cost Model sheet. The Supplier is responsible to meet all requirements of the Equipment Specification. 2. The Supplier is responsible to prove-out and validate Automated and Semi-Automated Gaging using the same methods as a fixture or gage as defined in this standard. In addition, the Supplier is responsible to verify all software applications and/or written code provided with the gage. This verification is to be performed by testing the input and output relationships and results with a minimum of 3 replications on 10 different parts. This verification study must be documented and supplied with the gage. 3. Automated and Semi-Automated gages must meet the YF Special Equipment General Specifications (SEGS) and Special Equipment Safety Specifications (SESS) as well as any applicable industry standards that may not be covered in the SESS and SEGS documents. If the Supplier is in need of a copy of these manuals or if aspects of these manuals are in question, contact the YF representative or Capital Equipment Buyer for clarification. 4. The Supplier is responsible for dry cycling the Automated and Semi-Automated gaging. This dry cycle will consist of a continuous 20 hours of operation or as defined by the YF representative. The dry cycle results must be documented and supplied with the gage.

Go to Glossary of Terms

Go to Table of Contents APPENDIX A – Documents

DESCRIPTION APPENDIX # PAGE # Supplier Internal Certification A1 20 Third Party Certification A2 21 Gage Repeatability Study A3 22 Gage Completion Check List A4 23 Supplier Quotation A5 24 Gage Concept Drawing A6 25 Supplier Identification Tag A7 26 Gage Request for Quote A8 27 Gage Instructions A9 29 Gage Repeatability Study Coordinates A10 30 Gage Cost Breakdown A11 31 Gage Preventive Maintenance Instruction A12 32 Attribute Study A13 33 Gage Timing Chart A14 34 Check Pin and Check Block Calculation A15 35 Ergonomic Repetition Benchmarks matrix A16 36 Ergonomic Force Benchmarks matrix A17 37 Ergonomic Posture Benchmarks matrix A18 38

APPENDIX A1. Supplier Internal Certification Return to Gage Build Requirements, Section A. Gage Certification, Item #2. Go to Appendix List Go to Table of Contents

ABC Corporation 123 West 12th Street Somewhere MI 99998 ABC Job#: 1290A Customer: Yangfeng Automotive Interiors Date Chkd: 04/Mar/00 Part Name: GMT236 Overhead Console Chkd By: D. P. Part Number: 9999998 File: 1290 START COORDINATES X = 3820.000 Y = -580.000 Z = 350.000

Detail No. X Master X Check X Diff Y Master Y Check Y Diff Z Master Z Check Z Diff. Vec. Dev. Chk Type Ln # Pt # Dim. Net Surface - Datum A1 1 2691.010 2690.981 -0.029 -827.998 -827.996 0.002 770.456 770.512 0.056 -0.063 Surf Rd 1 1 1 2691.010 2690.989 -0.021 -826.552 -826.497 0.055 794.329 794.346 0.017 0.061 Surf Rd 1 2 1 2702.691 2702.777 0.086 -827.116 -827.108 0.008 783.204 783.202 -0.002 -0.086 Surf Rd 1 3 1 2713.000 2712.996 -0.004 -827.788 -827.801 -0.013 770.456 770.499 0.043 0.045 Surf Rd 1 4 1 2713.000 2713.026 0.026 -827.998 -827.996 0.002 794.329 794.361 0.032 0.041 Surf Rd 1 5 Net Surface - Datum A2 2 3030.000 3030.001 0.001 -827.351 -827.359 -0.008 769.233 769.303 0.070 -0.070 Surf Rd 1 6 2 3030.000 3029.910 -0.090 -827.265 -827.259 0.006 749.962 749.976 0.014 0.091 Surf Rd 1 7 2 3042.000 3042.019 0.019 -827.279 -827.261 0.018 758.999 758.999 0.000 -0.026 Surf Rd 1 8 2 3055.000 3055.003 0.003EXAMPLE -827.198 -827.189 0.009 769.233 769.237 0.004 0.010 Surf Rd 1 9 2 3055.000 3054.995 -0.005 -827.000 -826.989 0.011 749.922 749.919 -0.003 0.012 Surf Rd 1 10 Net Surface - Datum A3 3 3262.000 3261.999 -0.001 -858.205 -858.199 0.006 920.000 919.999 -0.001 0.006 Surf Rd 1 11 3 3262.000 3262.000 0.000 -859.191 -859.215 -0.024 897.999 898.002 0.003 0.024 Surf Rd 1 12 3 3286.000 3286.000 0.000 -859.676 -859.728 -0.052 898.000 898.007 0.007 -0.052 Surf Rd 1 13 3 3286.000 3286.006 0.006 -837.471 -837.491 -0.020 920.000 920.000 0.000 0.021 Surf Rd 1 14 Centerline of Hole - Datum A3 4-WAY PIN 3275.806 3275.811 0.005 -858.726 -858.758 -0.032 911.116 911.200 0.084 0.090 Hole 1 15 6.789 Net Surface - Datum A4 4 3520.000 3520.009 0.009 -837.558 -837.577 -0.019 975.000 975.003 0.003 0.021 Surf Rd 1 16 4 3520.000 3520.010 0.010 -837.432 -837.466 -0.034 975.000 975.000 0.000 -0.035 Surf Rd 1 17 4 3545.000 3544.989 -0.011 -837.337 -837.378 -0.041 950.000 950.073 0.073 0.084 Surf Rd 1 18 4 3545.000 3545.000 0.000 -837.185 -837.247 -0.062 950.000 950.011 0.011 -0.063 Surf Rd 1 19 Centerline of Hole - Datum A4 2-Way PIN 3534.555 3534.547 -0.008 -837.471 -837.392 0.079 962.500 962.511 0.011 0.080 Hole 1 20 7.032

APPENDIX A2. Third Party Certification Return to Gage Build Requirements, Section B. Third Party Certification, Item #1. Go to Appendix List Go to Table of Contents

FCS - Fixture Certification Service

1001 Springs Road Somewhere, MI 99998 Office - (810) 123-0987 Fax - (810) 123-7890 FCS Job #: FCS9684 Customer: Yanfeng Automotive Interiors Date Chkd: 12/Mar/00 Part Name: GMT236 Overhead Console Chkd By: R. S. Part Number: 9999998 File: FCS9684

START COORDINATES X = 3820.000 Y = -580.000 Z = 350.000

Detail X X X Y Y Y Z Z Z Vec. Chk Ln Pt No. Master Check Diff Master Check Diff Master Check Diff Dev. Type # # Dim. Net Surface - Datum A1 1 2691.010 2691.005 -0.005 -827.998 -828.002 -0.004 770.456 770.521 0.065 -0.065 Surf Rd 1 1 1 2691.010 2690.998 -0.012 -826.552 -826.549 0.003 794.329 794.369 0.040 0.042 Surf Rd 1 2 1 2702.691 2702.721 0.030 -827.116 -827.191 -0.075 783.204 783.205 0.001 -0.081 Surf Rd 1 3 1 2713.000 2713.059 0.059 -827.788 -827.816 -0.028 770.456 770.502 0.046 0.080 Surf Rd 1 4 1 2713.000 2712.961 -0.039 -827.998 -828.009 -0.011 794.329 794.336 0.007 0.041 Surf Rd 1 5 Net Surface - Datum A2 2 3030.000 3030.058 0.058 -827.351 -827.419 -0.068 769.233 769.230 -0.003 -0.089 Surf Rd 1 6 2 3030.000 3030.021 0.021 -827.265 -827.305 -0.040 749.962 749.950 -0.012 0.047 Surf Rd 1 7 2 3042.000 3042.034 0.034 -827.279 -827.276 0.003 758.999 759.002 0.003 -0.034 Surf Rd 1 8 2 3055.000 3054.953 -0.047 -827.198 -827.191 0.007 769.233 769.190 -0.043 0.064 Surf Rd 1 9 2 3055.000 3055.035 0.035EXAMPLE -827.000 -827.069 -0.069 749.922 749.921 -0.001 0.077 Surf Rd 1 10 Net Surface - Datum A3 3 3262.000 3261.976 -0.024 -858.205 -858.210 -0.005 920.000 920.019 0.019 0.031 Surf Rd 1 11 3 3262.000 3262.000 0.000 -859.191 -859.150 0.041 897.999 898.052 0.053 0.067 Surf Rd 1 12 3 3286.000 3286.016 0.016 -859.676 -859.678 -0.002 898.000 898.017 0.017 -0.023 Surf Rd 1 13 3 3286.000 3286.012 0.012 -837.471 -837.416 0.055 920.000 920.009 0.009 0.057 Surf Rd 1 14 Centerline of Hole - Datum A3 4-WAY PIN 3275.806 3275.798 -0.008 -858.726 -858.715 0.011 911.116 911.112 -0.004 0.014 Boss 1 15 6.789 Net Surface - Datum A4 4 3520.000 3520.023 0.023 -837.558 -837.512 0.046 975.000 975.012 0.012 0.053 Surf Rd 1 16 4 3520.000 3520.010 0.010 -837.432 -837.500 -0.068 975.000 975.008 0.008 -0.069 Surf Rd 1 17 4 3545.000 3545.069 0.069 -837.337 -837.307 0.030 950.000 950.003 0.003 0.075 Surf Rd 1 18 4 3545.000 3545.004 0.004 -837.185 -837.178 0.007 950.000 950.019 0.019 -0.021 Surf Rd 1 19 Centerline of Hole - Datum A4 2-Way PIN 3534.555 3534.570 0.015 -837.471 -837.432 0.039 962.500 962.498 -0.002 0.042 Boss 1 20 7.032

APPENDIX A3. Gage Repeatability Study Return to Gage Build Requirements, Section E. Measurement System Analysis, Item #2. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A4. Gage Completion Check List Return to Gage Build Requirements, Section Q. Function Check, Item #1. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A5. Supplier Quotation Return to Quotation Requirements, Item #1. Go to Appendix List Go to Table of Contents

ABC Corporation 123 West 12th Street Somewhere MI 99998

March 30, 2000

Mr. John Johnson Yanfeng Automotive Interiors 921 E 32 nd Street Holland, MI 49435

Dear Mr. Johnson:

SUBJECT: CMM HOLDING FIXTURE – GMT236 Overhead Console

ABC Corporation is pleased to submit this quotation for your approval on the above subject. Our quotation is based on the following assumptions: Assumptions: - ABC Corporation to construct one (1) CMM holding fixture. - Design will be a computer generated 3D model with views and sections as required. - Customer to supply all CAD models and GDT information. - Fixture will be 180º out of body. - Fixture to include: • 1 - aluminum tooling plate with 4 jig feet • 4 – U/D net pads • 1 – C/C & F/A 4-way RFS tapered pin • 1 – C/C 2-way RFS tapered pin on a slide - Design and Build Requirements to meet Yanfeng and OEM gage standard Requirements. - Quote to include internal certification. - Cost and timing as stated in this letter will remain in effect for 60 day from the date of this letter. Cost Summary: EXAMPLEGMT236 Overhead Console Design (Delivery 2 wks) $ 750.00 Build (Delivery 5 wks) 5200.00 3rd Party Certification 350.00 Gage R & R study 250.00 GRAND TOTAL $ 6550.00

Thank you for giving ABC Corporation the opportunity to provide this quotation. If you have any questions, please feel free to contact me at (110) 123-4567.

Sincerely, Joe Smith Joe Smith Account Representative

FN: 330119.doc ABC #330119 cc: R. Thomas C. McPherson

APPENDIX A6. Gage Concept Drawing Return to Gage Design Requirements, Section A. Concept Drawing, Item #2. Go to Appendix List Go to Table of Contents

Gage Description: GMT236 Bracket Retainer Gage Number: 849999

2-way locator (Datum A2 & C) V. C. Plug gage

Net pad (Datum A3) Net pad (Datum A4)

EXAMPLE 6 mm Gap rail

Net pad (Datum A5)

4-way locator (Datum A1 & B)

3 mm Gap w/Nominal scribe

APPENDIX A7. Supplier Identification Tag Return to Gage Build Requirements, Section L. Labeling, Item #4. Go to Appendix List Go to Table of Contents

ABC Corporation

123 West 12th Street

Somewhere, MI 99998 Office - (810)123-4567

Fax - (810)123-7654

ABC Corp. JOB NUMBER: 1290A

Gage Number:EXAMPLE 849999

Part Description: GMT236 OHC Bracket Retainer

Customer: General Motors

Eng. Level: Rel.

APPENDIX A8. Gage Request for Quote (page 1) Return to General Requirements, Item #1. Return to General Requirements, Item #10. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A8. Gage Request for Quote (page 2) Return to General Requirements, Item #1. Return to General Requirements, Item #10. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A9. Gage Instructions Return to Gage Build Requirements, Section E. Measurement System Analysis, Item #2.1.1. Go to Appendix List Go to Table of Contents

GAGE OPERATING INSTRUCTIONS

GAGE #: 849999 GAGE NAME: GMT236 Overhead Console Bracket Retainer

E/C LEVEL: Rel E/C DATE: 10/14/99 RECERT. FREQ: Bi-Annually

TYPE OF FIXTURE: CMM SPC ATTR

GAGE CHECKS PART NUMBER(s): 999998 and 999999

INSTRUCTIONS:

1 Inspect fixture for damage.

2 Disengage all clamps.

3 Load part onto 4-way locator and 2-way locator pins, ensuring part is resting on all nets.

4 Starting with clamp #1, engage all clamps in sequence.

5 Turn the SPC indicator on, place it in the master set block and press the "zero" button.

6 Place the indicator in the SPC port and record reading.

7 Remove the indicator from the SPC port and place it in the storage box. 8 Place the plug gage into hole.EXAMPLE Record results. 9 Remove the plug gage and place it in its storage clip.

10 Using the Go/Nogo gage, inspect the gap rail at the opening in the part and at the front edge. Record result for each inspection area. 11 Place the plug gage into its storage clip.

12 Turn the SPC indicator off.

13 Open all clamps and remove part.

APPENDIX A10. Gage Repeatability Study Coordinates Return to Gage Build Requirements, Section E. Measurement System Analysis, Item #2.1.1. Go to Appendix List Go to Table of Contents

Z direction - Pt#1 X direction - Pt#1

Z direction - Pt#2

X direction - Pt#3

Y direction - Pt#3

Z direction - Pt#3

Y direction - Pt#2 X direction - Pt#2 Y direction - Pt#1

APPENDIX A11. Gage Cost Breakdown Return to General Requirements, Item #8. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A12. Gage Preventive Maintenance Instruction Return to Gage Build Requirements, Section G. Preventive Maintenance instructions, Item #1. Go to Appendix List Go to Table of Contents

APPENDIX A13. Attribute Study Return to Gage Build Requirements, Section E. Measurement System Analysis, Item #3. Go to Appendix List Go to Table of Contents

EXAMPLE

APPENDIX A14. Gage Timing Chart Return to Gage Build Requirements, Section H. Records, Item #1. Go to Appendix List Go to Table of Contents

3rd Quarter 4th Quarter 1st Quarter 2nd Quarter ID Task Name Duration Start Finish Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May 1 840123 - A pillar RH 6.2 wks Mon 8/7/00 Mon 9/18/00 840123 - A pillar RH 2 Gage Kickoff 0 days Mon 8/7/00 Mon 8/7/00 8/7/00 3 Design 2 wks Mon 8/7/00 Fri 8/18/00

4 Design Approval 1 day Mon 8/21/00 Mon 8/21/00

5 Build 3 wks Tue 8/22/00 Mon 9/11/00 6 Certification 1 day Tue 9/12/00 Tue 9/12/00 7 3rd Party Certification 2 days Wed 9/13/00 Thu 9/14/00

8 Gage R 1 day Fri 9/15/00 Fri 9/15/00

9 Function Check 1 day Mon 9/18/00 Mon 9/18/00 10 GAGE DELIVERY 0 days Mon 9/18/00 Mon 9/18/00 9/18/00 11 Quoted Timing 8 wks Mon 8/7/00 Fri 9/29/00 9/29/00 12 8.2 wks Mon 8/14/00 Mon 10/9/00 840124 - A pillar LH 840124 - A pillar LH 22 Quoted Timing 8 wks Mon 8/14/00 Fri 10/6/00 10/6/00 23 PPAP DATE 0 days Tue 3/6/01 Tue 3/6/01 3/6/01

APPENDIX A15. Check Pin and Check Block Calculation Return to Gage Design Requirements, Section B. Gage Design, Item #6. Go to Appendix List Go to Table of Contents

Go / Nogo Pin

2.25 mm 3.75 mm

Feeler rail = 3.00 mm Tolerance = +/- .75 mm Go pin = 3.00 - .75 = 2.25 mm Nogo pin = 3.00 + .75 = 3.75 mm

Virtual Condition Pin

5.00 mm

Hole Size = 8.00 mm Hole Size Tolerance = +/- .50 mm Hole Location Tolerance = +/- 2.50 mm Virtual Condition pin = 8.00 - .50 - 2.5 = 5.00 mm

APPENDIX A16. Ergonomic Repetition Benchmarks matrix Return to Safety and Ergonomic Requirements, Item #9. Go to Appendix List Go to Table of Contents

Repetition Benchmarks LOW MODERATE HIGH

Rapid Pace Leisurely Pace Steady Pace No Rest Pauses Frequent Pauses Infrequent Pauses Bottleneck Stations Non-cyclical Tasks High Frequency of Similar Tasks

APPENDIX A17. Ergonomic Force Benchmarks matrix Return to Safety and Ergonomic Requirements, Item #9. Go to Appendix List Go to Table of Contents

Force Benchmarks

TYPE OF HANDLING ILLUSTRATION LOW MODERATE HIGH

POWER GRIP < 14# 14# - 21# 21# - 48#

2 POINT PINCH < 3# 3# - 4.5# 4.5# - 9#

3 POINT PINCH < 4# 4# - 6# 6# - 14#

LATERAL PINCH < 4# 4# - 6# 6# - 14#

THUMB PUSH < 7# 7# - 10.5# 10.5# - 19#

PALM PRESS < 10# 10# - 15# 15# - 35#

FOOT CONTROL < 10# 10# - 16# 16# - 37#

NO EFFORT GREATEST EFFORT NEEDED POSSIBLE OTHER POSTURES (/= 60% Average Maximum Effort) Maximum Effort)

APPENDIX A18. Ergonomic Posture Benchmarks matrix (page 1) Return to Safety and Ergonomic Requirements, Item #9. Go to Appendix List Go to Table of Contents

Posture Benchmarks Low Risk Moderate Risk High Risk

15 - 30º EXTENSION 30 º EXTENSION 0-15º EXTENSION H 0 - 15º FLEXION >15º FLEXION

A OR N unsupported hand/forearm D

0-15º ULNAR DEVIATED WRIST 5-15º ULNAR DEVIATED WRIST >15º ULNAR DEVIATED WRIST a n d

W NEUTRAL & RELAXED FINGER TENSED / AWKWARD FINGER TENSED / AWKWARD FINGER R GRIP GRIP GRIP I S T

RELAXED or SUPPORTED <45º EXTENDED >70º FLEXION <70º FLEXION ELBOW ELBOW ELBOW

A R M NEUTRAL or SUPPORTED REACH & UNSUPPORTED UNSUPPORTED FOREARM FOREARM FOREARM a n d

S SUPPORTED or NEUTRAL UPPER REACHING / SHOULDER REACHING / SHOULDER ARM <60º FLEXION >60º FLEXION H O U L SLOUCHED / FORWARD ASSYMETRICAL / TENSED D NUETRAL SHOULDERS SHOULDERS SHOULDERS E R

APPENDIX A18. Ergonomic Posture Benchmarks matrix (page 2) Return to Safety and Ergonomic Requirements, Item #9. Go to Appendix List Go to Table of Contents

Posture Benchmarks Low Risk Moderate Risk High Risk

>15º FLEXION or CHIN NUETRAL <15º FLEXION & CHIN IN H PROTRUDED E N A E D C K &

RECLINE VERTICAL FLEXED

T o r s SYMETRICAL TWISTED BEND / REACH / LIFT o

D 15" - 24" TO SCREEN <16" TO SCREEN 8" - 12" TO SCREEN I 14" - 16" TO DOCUMENT V S I T E A W N C E OR HIGH RESOLUTION

15 - 30º <15 or <30º >10 or <35º A V N I G E L W E

Go to Table of Contents APPENDIX B - Diagrams

DESCRIPTION APPENDIX # PAGE # Toggle Clamp with Handle Stop B1 41 Toggle Clamp with Lock-out Pin B2 42 Hinged Drop Detail with Lock-out Pin B3 43 Minimum CMM Probe Access Distance B4 44 Gage Base Size B5 45 Tooling Ball Labeling B6 46 Go / NoGo Gage and Screw Pin Tethering and Storage B7 47 Removable Detail Tethering and Storage B8 48 Details Overhanging Base B9 49 J-Corner Identification B10 50 Jig Foot Location B11 51 Base Thickness Uniformity B12 52 Hole Clearance for CMM Access B13 53 Bullet Nose Dowel Location B14 54 Locating Pin with Lock-out Pin B15 55 Bayonet Clamp Location to Allow for CMM Access B16 56 Clamp Lock-out Mechanism B17 57 Handle Installation B18 58 Forklift Sleeve Installation B19 59 Datum Scheme for Base Certification B20 60 Gage Certification Datum Set-up B21 61 Check direction / Non-check Direction for Certification B22 62 Fastener Pin Representation B23 63 Eyebolt Installation B24 64 Tooling Ball Origin Identification B25 65 Clamping Direction B26 66 Tooling Hole B27 67 Certification of 2-way on a Slide B28 68

APPENDIX B1. Toggle Clamp with Handle Stop Return to Safety and Ergonomic Requirements, Item #4. Go to Appendix List Go to Table of Contents

PINCH POINT PINCH POINT

HANDLE STOP

APPENDIX B2. Toggle Clamp with Lock-out Pin Return to Safety and Ergonomic Requirements, Item #4. Go to Appendix List Go to Table of Contents

CLAMP

LOCK OUT PIN

TETHERING CABLE

APPENDIX B3. Hinge Drop Detail with Lock-out Pin Return to Safety and Ergonomic Requirements, Item #4. Return to Build Requirements, Section F. Hinged Details, Item #1. Go to Appendix List Go to Table of Contents

VIEW IN DIRECTION OF ARROW "A"

HINGED DETAIL HINGED DETAIL

LOCK OUT PIN LOCK OUT PIN

TETHERING CABLE

APPENDIX B4. Minimum CMM Probe Access Distance Return to Quotation Requirements, Item #4. Go to Appendix List Go to Table of Contents

PART

BASE MIN 9"

APPENDIX B5. Gage Base Size Return to Quotation Requirements, Item #5. Go to Appendix List Go to Table of Contents

PART

4" CLEAR AROUND ENTIRE PERIPHERY

TOOLING PLATE BASE CAST ALUMINUM BASE

W X L < 400 SQ IN W X L >/= 400 SQ IN

APPENDIX B6. Tooling Ball Labeling Return to Design Requirements, Section B. Design, Item #8. Return to Build Requirements, Section L. Labeling, Item #3.

Go to Appendix List Go to Table of Contents

THIS SURFACE 1162.3

TOOLING BALL "A" X=1600.00 Y=725.00 Z=1175.00

SECTION C-C

APPENDIX B7. Go / NoGo Gage and Screw Pin Tethering and Storage Return to Design Requirements, Section B. Gage Design, Item #14. Go to Appendix List Go to Table of Contents

SCREW PIN Go/Nogo GAGE

APPENDIX B8. Removable Detail Tethering and Storage Return to Design Requirements, Section B. Gage Design, Item #14. Go to Appendix List Go to Table of Contents

WORKING AREA STORAGE AREA

BUSHING

BULLET NOSE DOWEL

APPENDIX B9. Details Overhanging Base Return to Design Requirements, Section B. Gage Design, Item #20. Go to Appendix List Go to Table of Contents

UNACCAPTABLE

ACCEPTABLE ACCEPTABLE

APPENDIX B10. J-Corner Identification Return to Build Requirements, Section A. Bases, Item #3. Go to Appendix List Go to Table of Contents

THIS SURFACE 450.0 ΜΜ

APPENDIX B11. Jig Foot Location Return to Build Requirements, Section A. Bases, Item #4. Go to Appendix List Go to Table of Contents

< 200 sq. in > 200 sq. in

APPENDIX B12. Base Thickness Uniformity Return to Build Requirements, Section A. Bases, Item #6. Go to Appendix List Go to Table of Contents

APPENDIX B13. Hole Clearance for CMM Access Return to Build Requirements, Section D. Details, Item #7. Go to Appendix List Go to Table of Contents

Clearance

PART PART

APPENDIX B14. Bullet Nose Dowel Location Return to Build Requirements, Section E. Removable Details, Item #1. Go to Appendix List Go to Table of Contents

BUSHING

BULLET NOSE DOWEL

APPENDIX B15. Locating Pin with Lock-out Pin Return to Build Requirements, Section G. Locating Pins, Item #4. Go to Appendix List Go to Table of Contents

WORKING POSITION LOCK 0UT PIN POSITION

APPENDIX B16. Bayonet Clamp Location to Allow for CMM Access Return to Build Requirements, Section H. Clamps, Item #1. Go to Appendix List Go to Table of Contents

CLAMPED POSITION UNCLAMPED POSITION

PART PART

DOWEL DOWEL

APPENDIX B17. Clamp Lock-out Mechanism Return to Build Requirements, Section H. Clamps, Item #3. Go to Appendix List Go to Table of Contents

APPENDIX B18. Lift Handle Installation Return to Safety and Ergonomic Requirements, Item #6. Go to Appendix List Go to Table of Contents

22-30 INCHES 22-30 INCHES

TOTAL GAGE WEIGHT < 65 LBS TOTAL GAGE WEIGHT > 65 LBS < 100 LBS

APPENDIX B19. Forklift Sleeve Installation Return to Safety and Ergonomic Requirements, Item #6. Go to Appendix List Go to Table of Contents

Forklift Lifting Area

OVERALL GAGE WEIGHT > 100 LBS

* - 4” Riser Blocks may be attached to base feet for cart.

APPENDIX B20. Datum Scheme for Base Certification Return to Build Requirements, Section A. Bases, Item #1. Go to Appendix List Go to Table of Contents

BOTTOM OF JIG FEET

BOTTOM OF BASE BOTTOM VIEW

*DATUM "A" REFERENCE

* DATUM "A" REFERENCE (WITH JIG FEET) ** DATUM "A" REFERENCE (WITHOUT JIG FEET)

APPENDIX B21. Gage Certification Datum Set-up Return to Build Requirements, Section K. Build Tolerances, Note #1. Go to Appendix List Go to Table of Contents

APPENDIX B22. Check Direction / Non-check Direction for Certification Return to Build Requirements, Section K. Gage Build Tolerances, Note #2. Return to Build Requirements, Section K. Gage Build Tolerances, Note #3. Go to Appendix List Go to Table of Contents

CHECK DIRECTION NON-CHECK DIRECTION NON-CHECK DIRECTION NET SURFACE

NON-CHECK DIRECTION CHECK DIRECTION NON-CHECK DIRECTION SPC POINT NET PAD ATTRIBUTE RAIL

CHECK CHECK CHECK NON-CHECK DIRECTION DIRECTION DIRECTION DIRECTION

NO NET NO NET

NON-CHECK DIRECTION

ROUND LOCATOR (4-WAY) ROUND LOCATOR (2-WAY)

APPENDIX B23. Fastener Pin Representation Return to Build Requirements, Section D. Details, Item #10. Go to Appendix List Go to Table of Contents

APPENDIX B24. Eyebolt Installation Return to Safety and Ergonomic Requirements, Item #6. Go to Appendix List Go to Table of Contents

APPENDIX B25. Tooling Ball Origin Identification Return to Build Requirements, Section A. Bases, Item #1. Go to Appendix List Go to Table of Contents

Origin

APPENDIX B26. Clamping Direction Return to Build Requirements, Section H. Clamps, Item #2. Go to Appendix List Go to Table of Contents

APPENDIX B27. Tooling Hole and Surface Target Labeling Return to Design Requirements, Section B. Design, Item #8. Return to Build Requirements, Section L. Labeling, Item #3.

Go to Appendix List Go to Table of Contents

APPENDIX B28. Certification of 2-way on a Slide Return to Build Requirements, Section N. Gage Certification, Item #5.

Go to Appendix List Go to Table of Contents

AND (1 of the 2 selections)

Go to Table of Contents APPENDIX C – STANDARD MATERIAL LIST Return to Quotation Requirements, Item #2.

Product Code Material Applications* (grade) 6061 Details, Flush/feeler rails Aluminum Mic 6 Tooling Plate Bases 1018 Details, Net pads, Sheet metal representations Steel 1020 Details, Net pads, Sheet metal representations MP 1055 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations MP1054 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations Prolab 65 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations Fixture Plank Lab 1000 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations Ren Shape 450 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations Ren Shape 470 Flush / feeler rails, Attribute tub fixtures, Sheet metal representations

• Applications refer to examples and are not intended to be finite.

Go to Table of Contents APPENDIX D – REVISION TABLE

Level Date Description Release 03/15/02 a. Release for publication. 001 11/07/02 a. Added Gage Supplier signatures to Introduction page. b. Added note to Gage Build Requirements - Section K. Build Tolerance, All tolerances are in millimeters unless otherwise noted. c. Updated Gage Build Requirements - Section K. Build Tolerances to include the Check pin location tolerance. d. Updated Gage Build Requirements - Section K. Build Tolerances to include Go and Nogo pin size tolerances. 002 03/03/04 a. Changed Automotive Systems Group to Automotive Group. 003 05/05/04 a. Added reference to Gage Assumption/Gage Cost Model form in General Requirements #1 and #10. b. Added reference to Gage Assumption/Gage Cost Model form in Quotation Requirements #8. c. Added Quotation Requirements #9, referencing customer cost breakdowns using the Gage Assumptions / Gage Cost Model form. d. Revised wording of Gage Design Requirements - Section B. Gage Design #16 for clarification. e. Moved Gage Build Requirements - Section H Clamps #1 to Gage Design Requirements - Section B. Gage Design #23. Also, reworded entry for clarification. f. Revised wording of Gage Build Requirements - Section D. Details #1 for clarification. g. Revised wording of Gage Build Requirements - Section D. Details #4 for clarification. h. Revised wording of Gage Build Requirements - Section D. Details #5 for clarification. i. Revised wording of Gage Build Requirements - Section I Scribe Lines / Tolerance Bands #1 for clarification. j. Revised wording of Gage Build Requirements - Section I Scribe Lines / Tolerance Bands #2 for clarification. k. Revised wording of Gage Build Requirements - Section J SPC Indicators #2 for clarification. l. Changed Gage Build Requirements - Section K SPC Indicators #3 entry from center of indicator travel to approximate center of indicator travel. m. Changed Gage Build Requirements - Section K SPC Indicators #8 reference from tips must be secure to tips must be tightened. n. Revised wording of Gage Build Requirements - Section K SPC Indicators #9 for clarification. o. Revised wording of Gage Build Requirements - Section L Labeling #5 for clarification. p. Revised wording of Gage Build Requirements - Section N Gage Certification #1 for clarification. q. Revised wording of Gage Build Requirements - Section N Gage Certification #2 for clarification. r. Changed Gage Build Requirements - Section N Gage Certification #2 entry from one- direction check like a flush or feeler rail to one-direction check like a net point, flush rail, or feeler rail. s. Changed Gage Build Requirements - Section O Third Party Certification #3 entry by adding up to and including the internal and Third Party recertification. t. Changed Gage Build Requirements - Section P Gage Instructions #2 entry from it must include to they must include. u. Revised wording of Gage Build Requirements - Section Q Function Check #1 for clarification. v. Added Gage Assumption / Gage Cost Model to Appendix A – Documents as Appendix A19. 004 07/25/06 a. Changed all references of Gage Buyer to Gage Engineer. b. Corrected the Quotation Requirements #7 entry by changing the 600 in² reference to 400 in². c. Changed Gage Design Requirements - Section B. Gage Design #8 to include Tooling Holes and Surface Target. Added Tooling Holes and Surface Target picture to Appendix B – Diagrams as Appendix B27. d. Added wording to Gage Design Requirements - Section B. Gage Design #19 to include, including details that move (toggle clamps, hinge drops, etc.) e. Changed Gage Build Requirements - Section B. Tooling Balls to include reference to Tooling Holes. 70

f. Changed Table of Contents Gage Build Requirements – Section B to include Tooling Holes. g. Renumbered Table of Contents. h. Added reference to Gage Build Requirements - Section B. #1 to include Tooling Holes. i. Changed Gage Build Requirements - Section B. #2 to include reference for Tooling Holes size requirement. j. Changed Gage Build Requirements - Section I. Scribe Lines / Tolerance Bands #4 to have scribe lines on the gage base as an option, as determined by the Customer or YF Representative. k. Changed Gage Build Requirements – Section K. Build Tolerances Note #1 to include the reference of tooling holes. l. Changed Gage Build Requirements – Section L. Labeling #3 to include the reference of tooling holes. 005 12/01/12 a. Added YF Supplier Portal header and footer to cover page. a. Changed all references of Johnson Controls or JCI to Yanfeng Global Automotive Interiors or YF. b. Updated wording throughout standard. c. Added Gage Build Requirement – Section J. SPC Indicators to include all indicators must have a minimum metric discrimination of three (3) decimal places (.001 mm). d. Added Gage Build Requirement – Section J. SPC Indicators to include all indicators must have a dimensional certification, from the manufacturer, when shipped from the gage supplier. e. Added Gage Build Requirement – Section J. SPC Indicators to include all indicator collars must be placed within +/- 1.0 mm of the indicator’s center of travel. f. Added Gage Build Requirement – Section J. SPC Indicators to include all indicators must be identified with the gage supplier’s job number & SPC identification: NON-SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 1 SPC port on gage 1234-1 2 (or more) SPC ports on gage 1234-1/2/3/… SYMMETRICAL PARTS Quantity / Type of SPC port Terminology 006 07/29/17 1 SPC port for each hand on gage 1234LR-1 2 (or more) SPC ports for each hand on gage 1234LR-1/2/3/… g. Added Gage Build Requirement – Section K. Build Tolerances to include tolerance for 2-way on slide (pinned at center & pinned at one end) ¿ Ø 0.10 A B C Pinned at center of travel ¿ 0.10 A B C Pinned at end of travel (checked ¼to slide travel) h. Added Gage Build Requirement – Section L. Labeling to include all indicators must be identified with the gage supplier’s job number & SPC identification: i. Added Gage Build Requirement – Section N. Gage Certification to include all two way locators on a slide, must be certified in the center and at one end of the slide’s full travel. Each location must be pinned (for certification) and clearly identified on the gage certification. j. Revise Gage Build Requirement – Section R. Measurement System Analysis to make section better difined. k. Revise Gage Build Requirement – Section R. Measurement System Analysis to make section more clear. Added new requirements for plant representative. l. Updated Appendix F – Glossary of Terms to include definitions for LMB, MMB, RMB, CC, IC and SC.

Go to Table of Contents APPENDIX E – REFERENCE LIST

Reference Title Author / Publisher Publish Date ASME Y14.5-1994 Geometric Dimensioning and Tolerancing ASME 1/95 CG Model and Fixture Gage Build Standards CG Model and Fixture Unknown DaimlerChrylser Corporation – Chrysler Truck Platform Interior Systems Dimensional Quality Plan 6/00 Truck Platform Chrysler AME Gage Standards DaimlerChrylser Corporation 9/98 Chrysler Corporation Checking Fixture Design and Build Standards DaimlerChrylser Corporation 4/93 Ford Vehicle Operations Final Assembly Engineering Tooling Aids – Ford Motor Company 2/97 Design and Build Guidelines GM Checking Fixture/Gage Standards (PED:114) General Motors 10/01 GM Global Checking Fixture Standards General Motors 9/99 GM Mid/Lux Supplier Development/Quality Part Fixturing Design/Build General Motors Mid/Lux 4/96 Standards Division ISO Guide 25 Laboratory Certification ISO / IEC 12/90 ISO / IEC 17025 Laboratory Certification ISO / IEC 12/90 Jay Enn Gage Build Standards Jay Enn Corporation 1/97 Yanfeng Athens Plant General Gage Specifications Yanfeng Athens 6/98 Yanfeng Equipment Yanfeng Interiors Special Equipment General Specifications 5/01 Development Team Yanfeng Equipment Yanfeng Interiors Special Equipment General Specifications 5/01 Development Team Yanfeng Thermobond Headliner Substrate Standards Yanfeng Tooling 12/99 Yanfeng Acousticor Headliner Substrate Standards Yanfeng Tooling 10/98 Yanfeng Honda Business Unit Gage and Fixture Criteria Yanfeng Honda BU 4/99 Yanfeng Injection Mold Standards Yanfeng Tooling 1/00 Yanfeng Integration Center Gage (CMM Fixture) Development Criteria Yanfeng Integration Center 3/99 Yanfeng Lakeshore Gage Standards Yanfeng Lakeshore Unknown Yanfeng Reynosa Plant General Gage Specifications Yanfeng Reynosa 9/99 Chrysler/Ford/General Motors Measurement Systems Analysis Reference Manual Supplier Quality Requirements 6/98 Task Force MMMA Checking Fixture Tolerance Standard Mazda Motors 5/90 MP Components Gage Build Standards MP Components 1/99 Peterson Jig and Fixture, Inc. Fixture Build Standards Peterson Jig and Fixture Unknown Chrysler/Ford/General Motors Quality Systems Requirements - QS9000 Manual Supplier Quality Requirements 3/98 Task Force Chrysler/Ford/General Motors Quality Systems Requirements – Tooling & Equipment Supplement Tooling and Equipment 6/98 Representatives Supplier Quality Assurance Manual for Parts and Components (Section Toyota Motor Manufacturing 3/00 17 – Checking Fixtures, Gages and Test Equipment) North America, Inc.

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[11] Commented [D13]: An Attribute study analyzes the Appraiser variation ASME Y14.5M- ASME Y14.5.1M- ... [12] Anthropometry Attribute rail Attribute study Base (AV) 1994 1994 Commented [D14]: The base is the foundation for the... gage. [13] Commented [D9]: See Reproducibility. Cartesian Bayonet clamp Bias Body position Bullet-nose dowel Bushing Calibration coordinate system Commented [D10]: ASME Y14.5M-1994 is a Dimensioning... [9] Commented [D11]: ASME Y14.5.1M-1994 describes the Cast aluminum ... [10] CC Certification Certification target Clamp Clamping direction Clamp pressure base Commented [D15]: A bayonet clamp is a clamp that is... [14] Commented [D16]: Bias is the difference between the Coordinate ... [15] Concept drawing Contour template Datum Datum Axis Datum feature Datum point measuring machine Commented [D17]: Body position refers to the orientation... [16] of Commented [D18]: A bullet – nose dowel is a hardened Datum reference ... [17] Datum surface Datum target Design approval Detail Discrimination Drop template frame Commented [D19]: A bushing is a detail that is ... [18] Commented [D20]: Calibration is the comparison of a Equipment variation ... [19] Feeler rail Fixture Fixture plank Flatness Flush rail Gage (EV) Commented [D21]: A three dimensional system whereby... [20] Geometric Commented [D23]: Critical Characteristic. Designates... a[22] Gage design Gage R study Gage R&R study Gage instructions Gaging tolerance Dimensioning and Go/NoGo pin Tolerancing Commented [D24]: The gage certification is a document,... [23] Commented [D25]: A certification target is an area on... the [24] Hinge drop IC IGES I-J-K check Inspection ISO Guide 25 ISO Guide 17025 Commented [D26]: A clamp is a device that is used to... [25] Commented [D27]: The clamping direction is the orientation... [26] J corner Jig feet Linearity LMB LMC Maintainability Master set block Commented [D28]: The clamp pressure refers to the ... [27] Mean Time Commented [D22]: A cast aluminum base is a type of gage Mean Time Mean Time to Measurement Measurement Measurement ... [21] Between Measurement Between Failures Repair system system analysis system error Commented [D29]: A Concept drawing is a sketch of the Maintenance ... [28] Commented [D30]: A Contour template is a detail that is Measurement ... [29] Microslide MMB LMC NC machining Net surface Out of calibration uncertainty Commented [D32]: A datum is a theoretically exact point,... [31] Commented [D33]: A datum axis is an axis of a part feature Operator’s area of ... [32] Parallax error Parallelism Part Alignment Part orientation Phase I gage Phase II gage movement Commented [D34]: A datum feature is a feature on the... part[33] Commented [D35]: A datum point is a single coordinate... [34] on Pinch point Plug gage Precision Primary datum Profile of a line Profile of a surface QAF Commented [D31]: A Coordinate Measuring Machine... [30] Commented [D37]: A datum surface is an area of the... part [36] QS9000 Reliability Repeatability (EV) Reproducibility (AV) Resolution RFS RMB Commented [D38]: A datum target is a theoretically exact... [37] Commented [D39]: Design approval is a signature on the Set two check one Sheet metal Significant ... [38] Riser SC Scribe line Secondary datum check Representation characteristic Commented [D40]: A detail is a component of the gage... [39]and Commented [D41]: Discrimination refers to how finite... the [40] Simulated datum Site check SPC indicator SPC port Squareness Stability Stanchion Commented [D42]: A drop template is a detail that is ... [41] Commented [D36]: The datum reference frame refers... to [35] Third party Start Coordinates Step gage Sub-base TE9000 Tertiary datum Toggle clamp certification Commented [D44]: A feeler rail is an attribute rail that... [42] Commented [D45]: A fixture is defined as a device that... is[43] Tooling ball Tooling plate Total variation True position Tulip Vector check Virtual condition Commented [D46]: Fixture plank is a plastic composite... [44]that Commented [D47]: Flatness is a geometric control of... form [45] X-Y-Z coordinate Warranty system Commented [D48]: A flush rail is an attribute rail that ... [46] Commented [D49]: A gage is defined as an instrument... that[47] 73 Commented [D43]: See Repeatability.

Commented [D50]: A Gage design is a drawing (print)... that [48] Commented [D51]: A Gage R (Repeatability) study ... [49] Commented [D52]: A Gage R&R (Repeatability & ... [50] Commented [D53]: Gage instructions are a step by step... [51] Commented [D54]: Gaging tolerance refers to the tolerance... [52] Commented [D56]: Go / NoGo pins are details that are... [54] Commented [D55]: A method to minimize production... costs [53] Commented [D57]: A Hinge drop is a detail that used... to [55] flip Commented [D58]: Initial Characteristic. Designates... a part[56] Commented [D59]: Initial Graphics Exchange Standard.

Commented [D60]: An I-J-K check is a type of CMM ... [57] Commented [D61]: Inspection is the method of measuring,... [58] Commented [D62]: ISO Guide 25 is a standard that ... [59] Commented [D63]: ISO/IEC 17025 is a replacement .../ [60] Page 73: [1] Commented [D1] Definition A 2-way locator is a detail that restrains the part in two directions. For example, an RFS pin that is positioned into a slot is a 2-way locator, restraining movement within the width of the slot while allowing part movement within the length of the slot. 2-way locators on a gage may be MMC pins, RFS pins, bushings or net surfaces.

Page 73: [2] Commented [D2] Definition A 4-way locator is a detail that restrains the part in four directions. For example, an RFS pin that is positioned in a hole is a 4-way locator, restraining the part from moving side to side and forward to rearward. 4-way locators on a gage may be MMC pins, RFS pins, bushings or net surfaces.

Page 73: [3] Commented [D3] Definition 90º out of body defines the part orientation as it is loaded on the gage. The part is rotated 90º in one direction for easier part inspection and/or to minimize the gage cost.

Page 73: [4] Commented [D4] Definition 180º out of body defines the part orientation as it is loaded on the gage. The part is rotated 180º in one direction for easier part inspection and/or to minimize the gage cost.

Page 73: [5] Commented [D5] Definition American Association for Laboratory Accreditation.

Page 73: [6] Commented [D6] Definition Accuracy is defined as the closeness or nearness of the average of one or more measurements to an accepted reference measurement, value or standard.

Page 73: [7] Commented [D7] Definition ANOVA is a statistical technique for analyzing experimental data. It subdivides the total variation of a data set into meaningful component parts associated with specific sources of variation in order to test a hypothesis on the parameters of the model or to estimate variance components. There are three models: fixed, random, and mixed. More specifically to gaging, ANOVA is a statistical technique that is used to measure the Measurement error.

Page 73: [8] Commented [D8] Definition The study of the characteristics of mankind.

Page 73: [9] Commented [D10] Definition ASME Y14.5M-1994 is a Dimensioning and Tolerancing Standard or more commonly known as the GD&T standard. The scope of this standard is “to establish uniform practices for stating and interpreting dimensioning, tolerancing, and related requirements for use on engineering drawings and in related documents”.

Page 73: [10] Commented [D11] Definition ASME Y14.5.1M-1994 describes the Mathematical Definitions of the Dimensioning and Tolerancing standard ASME Y14.5M-1994. The scope of this standard is “to present a mathematical definition of geometrical dimensioning and tolerancing consistent with the principles and practices of ASME Y14.5M- 1994, enabling determination of actual values.”

Page 73: [11] Commented [D12] Definition An attribute rail is a gage detail that measures the contour of the part. A Go/NoGo pin or step gage is typically used with the rail to obtain attribute data, although variable data may be obtained by using a scale or calipers. Common attribute rails are called flush rails and feeler rails.

Page 73: [12] Commented [D13] Definition An Attribute study analyzes the variation of the measurement system using attribute data. This study consists of taking twenty parts, loading each on the gage, and recording the attribute measurements, for a total of two cycles. Then a second operator performs the two cycles and records the measurements.

Page 73: [13] Commented [D14] Definition The base is the foundation for the gage. All build dimensions are derived from the base. Each base surface must be flat and all sides must be square. Two types of bases are “Tooling Plate” and “Cast Aluminum”.

Page 73: [14] Commented [D15] Definition A bayonet clamp is a clamp that is engaged from the side and underneath or behind the part. It is simply a shaft with a flat piece of stock affixed perpendicular to it at one end. The shaft is spring loaded and located through a detail next to the net. The clamp is engaged by lifting up on the shaft, rotating it over the net and allowing the spring pressure to hold the part. The advantage of this clamp is that it allows maximum access for the inspection purposes.

Page 73: [15] Commented [D16] Definition Bias is the difference between the master (reference) measurement and the average of the actual measurements. Bias, with regard to gaging, refers to the entire measurement process (equipment, environment, operator and technique). When related to only a measuring instrument, bias can be referred to as the accuracy or systematic error and is the extent of which the instrument is out of calibration.

Page 73: [16] Commented [D17] Definition Body position refers to the orientation of the part as it fits in the vehicle.

Page 73: [17] Commented [D18] Definition A bullet – nose dowel is a hardened dowel with a rounded tip. This dowel is set into a surface that mates to another detail or the base plate so the tangent of the rounded tip is just above the mating surface. The detail is then located into position with the dowels inserted into hardened bushings. This set-up allows for consistent placement of a removable detail.

Page 73: [18] Commented [D19] Definition A bushing is a detail that is manufactured to accept a boss feature (or similar) on a part. When reference is made to a SPC bushing, the reference is the same as a SPC port.

Page 73: [19] Commented [D20] Definition Calibration is the comparison of a measurement instrument or system of unverified accuracy to a measurement instrument or system of a known accuracy to detect any variation from the required performance specification.

Page 73: [20] Commented [D21] Definition A three dimensional system whereby the position of a point can be defined with reference to a set of axes at right angles to each other.

Page 73: [21] Commented [D22] Definition A cast aluminum base is a type of gage base that is formed by pouring molten aluminum into a mold. This base is manufactured in an array of sizes, all with a standard stiffening rib design to maintain its dimensional integrity.

Page 73: [22] Commented [D23] Definition Critical Characteristic. Designates a part characteristic, on the part drawing, that has to be monitored per the control plan. A CC is typically safety related and is measured ongoing during production.

Page 73: [23] Commented [D24] Definition The gage certification is a document, electronic or hardcopy, that is the result of the dimensional inspection of the gage.

Page 73: [24] Commented [D25] Definition A certification target is an area on the base that is used as a start or set-up point to certify the fixture. To establish the correct set-up, six (6) targets are labeled on the base, three on top, two on a side and one on an adjacent side. These targets ensure that each time the gage is certified, the inspector will establish their point of origin in the same general area. Typically, these targets are identified by a stamped area on the base with a coordinate point called out next to it.

Page 73: [25] Commented [D26] Definition A clamp is a device that is used to restrain the part against a net surface. There are numerous types of clamps, some of which are toggle, bayonet, magnetic and plunger clamps.

Page 73: [26] Commented [D27] Definition The clamping direction is the orientation at which the clamp head travels to touch the part. Whenever possible, this travel should be 90º to the part surface.

Page 73: [27] Commented [D28] Definition The clamp pressure refers to the amount of force that is applied to the part by the clamp head when the clamp is engaged. Ultimately, the clamp pressure should be just strong enough to hold the part against the net surface.

Page 73: [28] Commented [D29] Definition A Concept drawing is a sketch of the gage or fixture that is an approximation of how the gage or fixture will look. The drawing is typically hand drawn, but may be computer generated. The intent of the drawing is to ensure that the gage supplier understands what was quoted. The concept can be used to minimize design changes and/or delays due to communication / interpretation errors.

Page 73: [29] Commented [D30] Definition A Contour template is a detail that is represents the surface of the part along a given section or area. Contour templates are typically used with hinge drops although they may be used with other types of flip mechanisms.

Page 73: [30] Commented [D31] Definition A Coordinate Measuring Machine (CMM) is a measuring device used to obtain dimensional variable data or attribute data. This machine is commonly used for dimensional layout of a part to determine if the part meets the print. It is a versatile machine that can accommodate various sized parts, their features, their gages and their coordinate systems.

Page 73: [31] Commented [D32] Definition A datum is a theoretically exact point, axis, or plane. It is considered the origin from which all geometric tolerancing is inspected to. Also see datum axis, datum target and datum surface for further clarification .

Page 73: [32] Commented [D33] Definition A datum axis is an axis of a part feature that is called out on the part print as a datum. A datum axis is considered the origin from which specified geometric tolerancing is inspected to. Some examples of a datum axis are the axis of a hole, slot, or a boss (see datum feature).

Page 73: [33] Commented [D34] Definition A datum feature is a feature on the part that is used to establish a datum. Examples of datum features are holes, slots, bosses, edges, ribs, and surfaces.

Page 73: [34] Commented [D35] Definition A datum point is a single coordinate on the part that is labeled on the part print as a datum target.

Page 73: [35] Commented [D36] Definition The datum reference frame refers to the datum(s) that are referenced in the feature control frame.

Page 73: [36] Commented [D37] Definition A datum surface is an area of the part (defined size or entire part surface feature) that is labeled on the part print as a datum target or datum.

Page 73: [37] Commented [D38] Definition A datum target is a theoretically exact point, line or area on the part that is used to establish a datum.

Page 73: [38] Commented [D39] Definition Design approval is a signature on the gage design hardcopy by the Yanfeng representative that is responsible for the gage. The design approval represents a consensus that the design is an accurate illustration of the gage as is to be built. This approval gives authorization to the Gage Supplier to continue onto the build phase.

Page 73: [39] Commented [D40] Definition A detail is a component of the gage and is listed on the gage design in the stock list. Examples of details are an angle bracket, an aluminum block, a spring and a zero block.

Page 73: [40] Commented [D41] Definition Discrimination refers to how finite the measurement scale is on the measurement device. For example, the discrimination of a SPC indicator may be 0.5 mm or 0.0005 mm.

Page 73: [41] Commented [D42] Definition A drop template is a detail that is attached to a hinged stanchion. This detail is typically an attribute rail or template. Drop templates are used when measurements are needed in “remote” areas of the part or when the part cannot be loaded if a permanent detail were affixed to the gage.

Page 73: [42] Commented [D44] Definition A feeler rail is an attribute rail that measures the contour of the part with a predetermined offset. This rail usually represents the comparative gaps between parts and is measured relative to that contour.

Page 73: [43] Commented [D45] Definition A fixture is defined as a device that is used to hold a part while various operations are performed on it. For instance, a fixture is used to hold a part for milling or CMM inspection.

Page 73: [44] Commented [D46] Definition Fixture plank is a plastic composite that is used for various details on a gage. Although it is not as dimensionally stable as steel or aluminum, it is easily machined, easily assembled, lighter, and costs less. Such details may include flush or feeler rails, part surface representations, and storage components.

Page 73: [45] Commented [D47] Definition Flatness is a geometric control of form that confirms the inspection points of a surface are on the same plane within a given tolerance. The flatness tolerance is defined as two parallel planes within which the measurement points must fall between.

Page 73: [46] Commented [D48] Definition A flush rail is an attribute rail that measures the contour of the part with a predetermined offset. This rail usually represents the comparative evenness of surfaces between parts and can be measured relative or 90º to that surface.

Page 73: [47] Commented [D49] Definition A gage is defined as an instrument that is used to measure the part. This measurement result can be attribute data or variable data. For instance, a gage is a CMM, a plug gage, a fixture with an attribute rail and a fixture with a fixed SPC indicator on it.

Page 73: [48] Commented [D50] Definition A Gage design is a drawing (print) that represents the composition of the gage. These drawings show how the part is to fit on the gage based on the datum scheme supplied. It also shows clamp orientation and any details used to measure the part. The design is typically used as a guide for the construction of the gage.

Page 73: [49] Commented [D51] Definition A Gage R (Repeatability) study analyzes the variation of the gage. This study uses a modified sum of the squares calculation to obtain a Gage R percentage. This study consists of taking a part, loading it on the gage, and recording the measurement(s), for a total of ten cycles.

Page 73: [50] Commented [D52] Definition A Gage R&R (Repeatability & Reproducibility) study analyzes the variation of the measurement system. There are three methods – the Range method, the Average & Range method and the ANOVA method. The Range method is used to approximate the measurement system’s variability. The Average & Range method is the most common and breaks down the measurement system into two components - Repeatability & Reproducibility. The ANOVA method is the most accurate of the three methods and can breakdown the measurement system into four components – parts, appraisers, interaction between parts and appraisers, and replication error due to the gage.

Page 73: [51] Commented [D53] Definition Gage instructions are a step by step procedure on how to load, measure and unload a part on the gage. The instructions should be written with the datum precedence in mind.

Page 73: [52] Commented [D54] Definition Gaging tolerance refers to the tolerance that is allowed in the machining and assembly of a gage. The OEMs have established gaging tolerances for various gage details. When a tolerance is not specified, a common gaging tolerance may be 10% of the part tolerance. The gaging tolerance is the tolerance that would be seen on a gage certification.

Page 73: [53] Commented [D55] Definition A method to minimize production costs by showing the dimension and tolerancing on a drawing while considering the functions and/or relationships of part features.

Page 73: [54] Commented [D56] Definition Go / NoGo pins are details that are manufactured to represent the outer bands of the feature tolerance and are cylinder shaped. The Go pin is the nominal dimension minus the tolerance while the NoGo pin is plus the tolerance. The Go/NoGo pins are typically used with an attribute rail to obtain attribute data.

Page 73: [55] Commented [D57] Definition A Hinge drop is a detail that used to flip or rotate attached details in and out of a measurement position. Most commonly, SPC ports or contour templates are attached to a hinge drop. A hinge drop is typically used when an inspection point is located too far inboard of the part to inspect using a stanchion or other common method.

Page 73: [56] Commented [D58] Definition Initial Characteristic. Designates a part characteristic, on the part drawing, that has to be monitored per the control plan. An IC is typically a dimensional characteristic that is measured for initial capability only.

Page 73: [57] Commented [D60] Definition An I-J-K check is a type of CMM (Coordinate Measuring Machine) inspection check and is identified by having a result in all three axes. When a CMM is used, it will drive to the preprogrammed point, measure it normal to the vector of the supplied I-J-K and report a result in each axis. This check is most commonly used for inspection of simple surfaces.

Page 73: [58] Commented [D61] Definition Inspection is the method of measuring, examining, testing, and gaging one or more characteristics of a product or service and comparing the results with specified requirements to determine whether conformity is achieved for each characteristic.

Page 73: [59] Commented [D62] Definition ISO Guide 25 is a standard that establishes general operating requirements for calibration and testing laboratories to ensure that their quality systems are recognized as competent to perform the respective tests.

Page 73: [60] Commented [D63] Definition ISO/IEC 17025 is a replacement / updated version of ISO Guide 25.

Page 73: [61] Commented [D64] Definition The J Corner is the corner on the base that establishes the dimensional origin of the gage. The J Corner is commonly identified with a corner of the base being ground at a 45º angle and is labeled with its respective body coordinate.

Page 73: [62] Commented [D65] Definition Jig feet are small details (typically 1” round stock) that are attached to the bottom of the base. These feet are used to raise the fixture to prevent the base bottom from damage.

Page 73: [63] Commented [D66] Definition Linearity is the difference in the bias (accuracy) over the anticipated operating range of the measuring instrument. Ideally, when graphing bias over the operating range, the linearity of the instrument should be a horizontal line (zero).

Page 73: [64] Commented [D67] Definition Least Material Boundary. Refers to the datum feature and defines the limits of its size based on the tolerance (or combination of tolerances) that exists on or inside the material of the feature(s).

Page 73: [65] Commented [D68] Definition Least Material Condition. Refers to a part feature of size and defines the condition in which the feature of size contains the least amount of material within the stated limits of size. Part feature examples would include the largest hole or smallest boss.

Page 73: [66] Commented [D69] Definition Maintainability is a characteristic of design, installation, and operation of machinery and equipment. Maintainability is expressed as the probability that a machine can be retained in or restored to specified operable condition within a specified interval of time, when maintenance is performed in accordance with prescribed procedures.

Page 73: [67] Commented [D70] Definition A Master set block is a detail that is used to zero the SPC indicator at nominal.

Page 73: [68] Commented [D71] Definition Mean Time Between Failures is a measure of reliability for repairable items - The mean number of life units during which all parts of the item perform within their specified limits, during a particular measurement interval under stated conditions.

Page 73: [69] Commented [D72] Definition Mean Time Between Maintenance is a measure of reliability taking into account the maintenance policy. The total number of life units extended by a given time, divided by the total number of maintenance events (scheduled and unscheduled) due to that item.

Page 73: [70] Commented [D73] Definition Mean Time to Repair is a measure of maintainability – The sum of corrective maintenance times at any specific level of repair, divided by the total number of failures within an item repaired at that level, during a particular interval under stated conditions.

Page 73: [71] Commented [D74] Definition A Measurement is a value or observation obtained as a result of inspecting an entity.

Page 73: [72] Commented [D75] Definition A Measurement system is everything that is used to produce a measurement. Some examples of the items that comprise the Measurement System are operators, measurement instruments, gages, gage instructions and software.

Page 73: [73] Commented [D76] Definition Measurement System Analysis is the process of examining the measurement system to determine what the measurement system error is. There are two common studies that are used to accomplish this – Gage Repeatability and Reproducibility (G.R.R.) and Analysis of Variance (ANOVA).

Page 73: [74] Commented [D77] Definition The Measurement System Error (variation) is the collective error found in the gage, operators and measurement device. This error is known as Equipment Variation-Repeatability, Appraiser Variation- Reproducibility and Measurement Variation-Linearity, Bias and Stability.

Page 73: [75] Commented [D78] Definition Measurement uncertainty is defined as a number that represents the estimated amount of error or deviation from the true measurement that can be expected when measuring with a specific piece of equipment. This error or deviation is determined by taking all the certification masters’ uncertainty figures and performing a statistical calculation. It must be understood that these certification masters are defined as all of the masters that are traceable back to the know standard that is used to certify that piece of equipment.

Page 73: [76] Commented [D79] Definition A Micro slide is a detail that allows for precise movement in two directions. The slide is typically used for a 2-way locator detail for a feature of size in the part.

Page 73: [77] Commented [D80] Definition Maximum Material Boundary. Refers to the datum feature and defines the limits of its size based on the tolerance (or combination of tolerances) that exists on or outside the material of the feature(s).

Page 73: [78] Commented [D81] Definition Maximum Material Condition. Refers to a part feature of size and defines the condition in which the feature of size contains the maximum amount of material within the stated limits of size. Part feature examples would include the smallest hole or largest boss.

Page 73: [79] Commented [D82] Definition The technique of controlling a machine by using command instructions in coded numerical format.

Page 73: [80] Commented [D83] Definition A Net Surface is a detail that represents one of the datums of a part. Typically it represents the mating part’s locating surface.

Page 73: [81] Commented [D84] Definition Out of calibration is the event in which a piece of equipment that is used to build and/or certify the gage or fixture is uncalibrated, past due on its scheduled calibration, or broken.

Page 73: [82] Commented [D85] Definition The operator’s area of movement is any area(s) on the gage that the operator may touch, lean over, or move by. Theoretically, the entire fixture is in the operator’s area of movement, but specifically this term pertains to the area(s) on the gage as it would be used on the manufacturing floor.

Page 73: [83] Commented [D86] Definition Parallax error is a visual inspection error that is caused from not inspecting a part’s edge perpendicular to its inspection reference. This error is more apt to occur if this visual site line departs from 90º or the part edge is held further away from the master reference.

Page 73: [84] Commented [D87] Definition Parallelism is a geometric control of orientation that confirms the inspection points of a surface, line, or axis is parallel to a datum within a given tolerance from the referenced datum(s). The parallelism tolerance zone is defined as two parallel planes, two parallel lines or a cylindrical zone within which the measurement points must fall between.

Page 73: [85] Commented [D88] Definition Part alignment refers to the process that takes place in a computer program during which it overlays the part inspection data defining the datum surfaces and “aligns” this data to the master data or math model. This computer process is an iterative process that continues until the optimum alignment is achieved. Also, part alignment refers to how the part is nested and/or fixtured in relation to how it fits into the vehicle. Refer to part orientation.

Page 73: [86] Commented [D89] Definition Part orientation defines the position of the part as different actions or functions are performed on it in relation to the designed (math model) position. This part position can be in any direction or rotation, but some of the most common orientations are die draw, workline, 90º out of body, and 180º out of body.

Page 73: [87] Commented [D90] Definition A Phase I gage is a gage that is built as a CMM holding fixture.

Page 73: [88] Commented [D91] Definition A Phase II gage is a CMM holding fixture that is revised to add attribute rails and/or SPC bushings for in- process inspection.

Page 73: [89] Commented [D92] Definition A pinch point refers to a point or location at which a detail or combination of details that move in such a manner to cause an operator to be pinched. A toggle clamp is the most common detail to have a pinch point. This would occur when the clamp is installed without a handle stop. The operator would open the clamp and the clamp arm would pinch the operator’s hand.

Page 73: [90] Commented [D93] Definition A Plug gage is a detail that is manufactured to represent the Virtual Condition of a part feature. This gage is typically located in a keyed bushing and measures the part feature by having a constant gap between itself and the part. This gap can then be measured with Go/Nogo pins or a scale. Plug gages may also be used to obtain attribute data by themselves. This is done by simply manufacturing a Go plug gage and a Nogo plug gage. Like the Go/NoGo pins, the Go side is the nominal dimension minus the tolerance while the NoGo side is plus the tolerance.

Page 73: [91] Commented [D94] Definition Precision is the closeness or nearness of a group of measurements to each other.

Page 73: [92] Commented [D95] Definition The Primary Datum refers to the datum plane that is established by the part.

Page 73: [93] Commented [D96] Definition Profile of a line is a geometric control of form or size, form, orientation and location that confirms the inspection points of a section line on a surface within a given tolerance. Profile of a line does not necessarily have to reference the datum(s). The Profile of a line tolerance zone is defined as two lines on opposite sides of the true form equidistant from that true form of the surface section. These lines may be unequal from the true form, but a note must be placed under the feature control frame and/or phantom lines need to be used to clarify the tolerance zone.

Page 73: [94] Commented [D97] Definition Profile of a surface is a geometric control of form or size, form, orientation and location that confirms the inspection points of a surface within a given tolerance. Profile of a surface does not necessarily have to reference the datum(s). The Profile of a surface tolerance zone is defined as two profile areas on opposite sides of the true form equidistant from that true form of the surface. These profile areas may be unequal from the true form, but a note must be placed under the feature control frame and/or phantom surfaces need to be used to clarify the tolerance zone.

Page 73: [95] Commented [D98] Definition A Quality Assurance Fixture is a fixture that is built to represent all the nominal attachments of a vehicle’s interior or exterior and is used to evaluate part to part and part to body fit.

Page 73: [96] Commented [D99] Definition QS9000 refers to a Quality System Requirements standard that was developed to define the fundamental quality system expectations of Chrysler, Ford, General motors, Truck Manufactures and to the subscribing companies for internal and external suppliers of production and service parts and materials.

Page 73: [97] Commented [D100] Definition Reliability is the probability that machinery and equipment can perform continuously for a specified interval of time without failure, when operating under stated conditions.

Page 73: [98] Commented [D101] Definition Repeatability is the measurement error due to the equipment, also referred to as the Equipment Variation (EV). Repeatability measures the measurement variation of one part sampled several times with the same operator and the same gage.

Page 73: [99] Commented [D102] Definition Reproducibility is the measurement error due to the operator, also referred to as the Appraiser Variation (AV). Reproducibility measures the average measurements by several operators using the same part and the same gage.

Page 73: [100] Commented [D103] Definition Resolution refers to how defined the measurement scale is on a gage. For instance, a typical tape measure would have a resolution of 1/16” (.06”), whereas a micrometer may have a resolution of .0001”.

Page 73: [101] Commented [D104] Definition Regardless of Feature Size. The simulated datum feature is built to accommodate any feature size within its respective size tolerance.

Page 73: [102] Commented [D105] Definition Regardless of Material Boundary. Refers to the datum feature and indicates that the datum feature simulator progresses from MMB toward LMB until it makes maximum contact with the extremities of a feature(s).

Page 73: [103] Commented [D106] Definition A riser is a detail that is used to locate various details (net surfaces, SPC ports, Feeler rails, Flush rails, etc.) to a proper height and/or orientation.

Page 73: [104] Commented [D107] Definition Significant Characteristic. Designates a part characteristic, on the part drawing, that has to be monitored per the control plan. An SC is typically a dimensional characteristic that is measured ongoing during production.

Page 73: [105] Commented [D108] Definition

A scribe line is a line that is etched into a detail on a gage. This etched line can represent a nominal part line, a tolerance band or a part reference location. The scribe line is also known as a site check.

Page 73: [106] Commented [D109] Definition The Secondary Datum refers to the datum line that is established by the part.

Page 73: [107] Commented [D110] Definition A Set two-check one check is a type of CMM (Coordinate Measuring Machine) inspection check and is identified by having a result in one of the three axes. When a CMM is used, it will drive to a preprogrammed point in the first axis, drive to a preprogrammed point in the second axis and then measure the part, reporting a result in the third axis. This check is most commonly used for inspection of edges and is also referred to as a shank check.

Page 73: [108] Commented [D111] Definition A sheet metal representation is a detail that has been cut to simulate the sheet metal. The replica may be as complicated as duplicating the attachment schemes or as simple as duplicating the profile.

Page 73: [109] Commented [D112] Definition A Significant Characteristic (SC) is defined as a part attribute or trait that has been determined to be important for ongoing control. SCs are shown as inverted deltas, pentagons, critical characteristics and other symbols, acronyms and labels. An SC may affect assembly, processing, inspection, or validation of the part. Reference the FMEA form (WW-PLUS-FR-01-31) for specific customer characteristic symbols.

Page 73: [110] Commented [D113] Definition A Simulated datum is a point, line or plane established by processing or inspection equipment, such as a surface plate, a gage detail, a chuck or a mandrel.

Page 73: [111] Commented [D114] Definition A site check is a line that is etched into or painted on a detail on a gage. This check can represent a nominal feature line, a tolerance band or a part reference location. The site check is also known as a scribe line.

Page 73: [112] Commented [D115] Definition A SPC indicator is a measurement instrument used to take variable data on the part. The indicator is set to nominal by placing it into the master set block, depressing the zero button on the indicator and then measuring the part by placing it in a SPC port.

Page 73: [113] Commented [D116] Definition A SPC port is a bushing that is offset from a point that is being measured, either on the part or on a gage detail. The SPC port is used to locate the SPC indicator to take variable data.

Page 73: [114] Commented [D117] Definition Squareness is defined as control to ensure a shape is a quadrangle within a specified tolerance. This squareness tolerance zone is defined as two parallel planes within which the measurement points must fall between.

Page 73: [115] Commented [D118] Definition Stability is the bias of the measurement instrument as seen over time. Typically, stability will measure the wear of the gage.

Page 73: [116] Commented [D119] Definition A stanchion is a detail that is used to locate various gaging features (net surfaces, SPC ports, Feeler rails, Flush rails, etc.) in their proper height and/or orientation. Stanchions are more commonly known as risers or angle brackets.

Page 73: [117] Commented [D120] Definition The start coordinates are theoretical X, Y, Z (body) coordinates that are identified on the gage base to allow the inspection data or certification data to be orientated so a comparison to the math model can occur. These body coordinates are labeled on the base, next to a tooling ball, the J corner or certification targets.

Page 73: [118] Commented [D121] Definition A Step gage is a detail that is manufactured to represent the outer bands of the part tolerance and is square shaped. Unlike the Go/NoGo pins, the Go side is the nominal dimension plus the tolerance while the NoGo side is minus the tolerance. A step gage is typically used to measure the flatness, step height or flushness of a part with attribute data results.

Page 73: [119] Commented [D122] Definition Sub-base pertains to a gage build method of building fixtures with smaller bases onto one common large base. Each of the smaller fixtures would typically be a portion or section of the overall gage. This method allows the gage supplier to build a large fixture with smaller milling and inspection equipment.

Page 73: [120] Commented [D123] Definition TE9000 refers to a Quality System Requirements standard that was developed to define the fundamental quality system expectations of Chrysler, Ford, General motors, Truck Manufactures and to the subscribing companies for suppliers of tooling and equipment.

Page 73: [121] Commented [D124] Definition The Tertiary Datum refers to the datum point that is established by the part.

Page 73: [122] Commented [D125] Definition A Third party certification is a certification that is performed by an independent laboratory. This certification is performed by verifying the original certification data and inspecting the gage or developing new certification data and inspecting the gage.

Page 73: [123] Commented [D126] Definition A toggle clamp is a device that is used to restrain the part against a net surface. A toggle clamp is operated by a linkage system of levers and pivots.

Page 73: [124] Commented [D127] Definition A Tooling ball is a ball that the CMM (Coordinate Measuring Machine) uses to establish the dimensional origin of the gage in order to layout the part. The CMM must use a minimum of three tooling balls to establish its three axes’ origin. A J Corner may be used also, although Tooling balls are more reliable because they are positioned in from the edge of the base. A tooling ball can also be used as a single point datum (see datum target).

Page 73: [125] Commented [D128] Definition Tooling plate is an aluminum sheet of various thickness’’ and sizes. While the size (L x W) of the tooling plate is dictated by part size, the thickness is typically a standard range from .75” – 1.25”. It is used as the base of gage or fixture.

Page 73: [126] Commented [D129] Definition Total Variation is defined as the combined variation of the Repeatability and Reproducibility (R&R) variation and the Part variation (PV), which is done by summing the squares of both and then taking the square root. The Total Variation calculation may be substituted with a process variation calculation if the process variation is known. Also, the Part Tolerance may be used in the place the Total Variation (TV) as the denominator in the calculation.

Page 73: [127] Commented [D130] Definition True position is the theoretical exact location of a feature established by basic dimensions. See also Position.

Page 73: [128] Commented [D131] Definition A Tulip is a Yanfeng Interiors designation for a significant characteristic. Reference the glossary term Significant Characteristic and/or the Characteristic Management Standard (WW-PLUS-ST-02-01) for clarification.

Page 73: [129] Commented [D132] Definition A Vector check is a type of CMM (Coordinate Measuring Machine) inspection method and is identified by having one result for all three axes. When a CMM is used, it will drive to the surface around the preprogrammed point, sample the surface, retract from the surface, approach the surface normal to it and then measure the point, reporting only one result. This check is most commonly used for inspection of compound surfaces.

Page 73: [130] Commented [D133] Definition Virtual Condition is the worse case boundary of all of the part feature of size tolerances. A Virtual Condition plug gage will take into account the feature size tolerance, position tolerance and any other applicable tolerances.

Page 73: [131] Commented [D134] Definition Warranty is a form of assurance that a product is fit for use or, if defective, that the customer will receive some extent of compensation.

Page 73: [132] Commented [D135] Definition The X-Y-Z coordinate system is the same as the Cartesian coordinate system. When related to the automotive industry, the X direction is fore/aft, the Y direction is cross car and the Z direction is up/down. The origin point varies from company to company, but one of the most common is the center of the driver’s side front axle for X and Z and the center plane of the car for Y. All dimensional information is taken from this origin point.