Originator: Stephen I. Dains/sdains
Page 5
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/6/2004
sketches, process and inspection sheets, and visual aids. Theuseof sucha symbol is highly
recommended toeffectively communicateanddocument critical elements throughout the
organization. Anexamplewouldbe the inverteddelta (
▼
) used in the
IncompleteVehicle
Manual
. This symbol canbeusedwitha critical part or process tonote its importance. See
D0405
D0401
Aprocess flow chart is recommended. This canhelp in findingweaknesses in themanufacturing
process and identifying critical elements. The chart should show the key elements of thebuilder's
handlingof the vehicle from receipt fromFord to customer delivery.
D0402
Informationdefiningprocess control shouldbe communicated to theemployees andavailableat
assembly stations as reference for newemployees. Theuseof process sheets or visual aids
(sketches, photographs, placards andmock-ups of component assemblies) is recommended to
assure correct procedures are followed.
D0403 Eachemployee shouldbe trained tounderstandall process directionpertinent tohis/her specific
job function. Training should include themeaning and importanceof critical elementswithin the
productionprocesswith specific attention toC/FMVSS, andguidelines in referencedFord
publications as they relate to this function. Employees need tobemadeawareof how their job
function canaffect the safety andquality of theendproduct.
D0404
Theassembler or foreman should signoff thework as it is performed. Adesignatedquality
inspector should signoff critical items, including repairs.
D0405 Elementswithin themanufacturingprocess that areof a critical naturemust be visibly identified.
Aunique symbol identifying critical elements shouldbeadoptedand shouldbeusedondrawings,
process sheets, and visual aids or sketches at assembly or workstations.
D0406
Aprocesscontrolmust becreated for eachcritical element.
Onceall critical elementswithin yourmanufacturingprocess havebeen identified, process control
documentationmust be created for eachof them to assure that eachunit built achieves the same
consistently high level of quality, safety, reliability, and customer satisfaction.
Toproperly control each critical element within themanufacturingprocess, process directionmust
be createdand communicated toproductionemployees throughuseof the followingprocess
control tools:
•
IN-PROCESSANDFINAL INSPECTIONSIGN-OFFSHEETS (often included ina Traveler):
These sign-off sheets includeentries for all critical elementswithaplace for the signatures of
both theoperator and inspector toprovideacknowledgment that eachoperationwas
performedaccording topredeterminedprocess direction. Non-critical itemsmay alsobe
includedon the sheets, but theremust bedifferentiationbetween the critical andnon-critical
items.
Management shouldassure that sign-off sheets arenot signed-off prior toaccomplishment of
thework. As each vehiclegoes intoproduction, an in-process sign-off sheet is placed in the
unit and travelswith it through final production. Upon vehicle completion, the final inspection
is conductedand the final inspection sign-off sheet is filledout. Both sign-off sheets should
thenbe filedwith the vehicle's recordswhere theymay later serve toaid inproblem/warranty
analysis or beusedby quality control inspectors.
•
PROCESSSHEETS include informationon the sequenceof operations, tool usage, torque
setting, component usage, andany other relevant information. These sheets are kept at the
appropriatework- stations and reviewedwithnewemployees.
•
VISUALAIDS: These canbe sketches, illustrations, or photographs that show the correct
way toassembleor install items. Mock-ups of component assemblies canalsobeused.
