Originator: Stephen I. Dains/sdains
Page 6
Date Issued: 2-16-04
guidebookcommon spring 2004.doc
DateRevised: 5/6/2004
D0407
Torque specificationsmust be specifically calledout for all critical fasteners. Assemblersmust be
suppliedwith theproper tools andequipment to insure the specificationswill bemet.
All OEM components that are loosenedor removedduring constructionmust beproperly re-
attached in their proper orientationandat OEM recommended torque. Refer to theapplicable
Ford
ShopManual
for specific details. Theuse of new fastenersmay be required.
D0408
Theabovedescribed traveler documents all pertinent events constituting theassembly history of
the vehicle. Employees shouldbe trained to include informationabout part substitution, an
alternateemployeeat thework station, or anything that is adeviation from thenormal process. A
traveler of this typegreatly enhances root-causeproblem solving investigations.
D0409
A formal analysis shouldbe conducted toanticipateproblemswhenany change is required in the
designor buildprocess. Any correctiveactions shouldbe takenbefore aproblemoccurs.
D0500 QUALITYCONTROL
Themajor elements of quality control are voice-of-the-customer, designanalysis, and checking for
defects. Onceprocess control (or production consistency) is established it is important to
recognize that the customer is theultimate judgeof quality. For this reasonagoodquality plan
has togobeyond thewarranty systemand continually survey the customer's real needs and
expectations. This feedback is required to determinewhat changes areneeded tomaintain
customer satisfactionand confidence. Thenext step is toanalyze thedesign for comparison to
thequality indicators obtained from the customer survey. Theanalysis of "squawks" at theendof
theassembly lineandothermethods of inspecting for defects shouldbeemployed. If the volume
is largeenough, statistical samplingmay beused tomakequality control cost effective.
D0501
TheFinal StageManufacturer should implement a customer survey, takenafter a significant time
in service, tomeasureandmaintain customer satisfaction.
D0502
Awarranty analysis system shouldbeused to identify trends in recurringquality concerns. The
trends shouldbedocumented, aswell as theproduction change(s) incorporated to resolveeach
concern.
D0503
Suppliersmust certify the critical characteristics of their components inwriting. Outside suppliers
that supply "critical" components shouldprovidewrittendocumentation that these components
complywithany functional performance requirements (i.e. temperature ratings for under hood
wiring). If theC/FMVSS complianceoffered is basedupon testing, the supplier shouldprovide
test results for you to review (check for reasonableness) and filewithall other C/FMVSS
compliancedata. As final stagemanufacturer, youare responsible for complyingwithall
C/FMVSS requirements.
Fasteners that arepart of a critical attachment must have certification from the fastener supplier
that theengineering specifications, suchas grade strength, bearingarea, and surface finish, have
beenmet. These certifications are tobe filed in thepurchasingand/or engineeringoffices. It is
suggested theperson responsible for C/FMVSS compliance keepa copy.
D0504
Torqueaudits shouldbe incorporated for critical fasteners, with theaudit resultsmaintainedon
file. Note that anaudit is aquality check performedafter aprocess is complete.
Statistical process control (SPC)may beapplied todetermineanappropriateaudit interval oncea
sufficient databasehas beendeveloped.
D0505
Tools and test equipment used for installation/verificationof critical items shouldbe inspectedor
calibratedor otherwisemaintainedona scheduledbasis. Tools that shouldbe included in this
processwould include torquewrenches, electrical meters and system testers, pressuregauges,
air pressure regulators, weldingequipment etc.. Consult the tool manufacturer for help in
determining theappropriate schedule.
D0506
Engineering specifications shouldbeused for purchasing component parts, and toensure that the
