C346 Poka Yoke - Front & Rear line

Poka Yoke Check List C346 Main Line

• Auditor

• Conducted on

  Date

Station #: Invert C346 Error Proofing Identification: Recliner Traceability

• Process - Ask operator to only scan the recliner once
  Verification - Screen should not go to next step without two scans

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-040-10 Error Proofing Identification: Advance pallet prior to scanning build label

• Process - Do not scan build label
  Verification - Pallet will not advance if label is not scanned

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-040-10 Error Proofing Identification: Correct Driver track loaded to build label

• Process - Ask operator to scan incorrect track and verify result
  Verification - Screen should turn "Red with Mismatch" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-040-10 Error Proofing Identification: Driver inner side shield ring

• Process - Do not torque in side shield ring
  Verification - Pallet will not advance if side shield ring is not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-060-10 Error Proofing Identification: Advance pallet prior to scanning build label

• Process - Do not scan build label
  Verification - Pallet will not advance if label is not scanned

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-060-10 Error Proofing Identification: Correct Passenger track loaded to build pallet

• Process - Ask operator to scan incorrect track and verify result
  Verification - Screen should turn "Red with Mismatch" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-060-10 Error Proofing Identification: Passenger inner side shield ring

• Process - Do not torque in side shield ring
  Verification - Pallet will not advance if side shield ring is not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-080-10/20 Error Proofing Identification: Correct FSC

• Process - Ask operator to scan a different FSC from the bin
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-110-10 Error Proofing Identification: Correct FSB PA

• Process - Ask operator to scan a different seat from the rack
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-130-10 Error Proofing Identification: Correct FSB DR

• Process - Ask operator to scan a different seat from the rack
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-170-10 Error Proofing Identification: Back-Up Marriage

• Process - Ask operator not to scan Passenger Seatbelt
  Verification - Screen should not advance if scan is not complete

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

• Process - Ask operator not to scan Driver Seatbelt
  Verification - Screen should not advance if scan is not complete

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-180-10 Error Proofing Identification: Manual 4-way metal lever to clutch; LH OB Side Shield; LH OB SS Bracket

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-190-10 Error Proofing Identification: Driver front SS screw and Side Shields

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-210-10 Error Proofing Identification: Headrest Scan, I/B SS screw, Side shields

• Process - Ask operator to Scan the DR H/R serial number twice.
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-260-10 Error Proofing Identification: Driver front SS Screw and side shields

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-280-10 Error Proofing Identification: Passenger front SS Screw

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-300-10/20 Error Proofing Identification: Witness mark wire connections after connecting wires

• Process - Verify that the operator is witness marking connections after connection is complete
  Verification - Wire connections should be witness marked before allowing the seat to advance

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-310-10 Error Proofing Identification: Driver & Passenger Rear SS Screw

• Process - Ask operator to miss one fastener and verify results
  Verification - Pallet will not advance if all fasteners are not torqued

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-330 Error Proofing Identification: Super Seater

• Process - Verify super seater has fully seated Manual recliner handles
  Verification - If recliner handles have not been fully seated, inform Quality inspection to fully seat with aid of modified mallet

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-390-10 Error Proofing Identification: Final Inspection

• Process - Ask operator to select different trim style on LPS
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

• Process - Ask operator to select different Headrest style on LPS
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-580-10 Error Proofing Identification: Bag & Tag

• Process - Ask operator to scan different DR & PS labels of different seats
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: F2-770-10 (repair) Error Proofing Identification: Spatial Arm

• Process - Ask operator not to torque the bolts/screws correctly
  Verification - pallet will not advance

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-10-10/20 (40% Rear Seat Cushion) Error Proofing Identification: Trim

• Process - Ask Operator to scan incorrect trim label for the build label
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-20-10/20 (60% Rear Seat Cushion) Error Proofing Identification: Trim

• Process - Ask Operator to scan incorrect trim label for the build label
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-30-10 (100% Rear Seat Cushion) Error Proofing Identification: Trim

• Process - Ask Operator to scan incorrect trim label for the build label
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-50-10 (40% Rear Seat Back) Error Proofing Identification: Trim & frame

• Process - Ask Operator to scan incorrect trim & frame label for the build label
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-50-20/30 (40% Rear Seat Back) Error Proofing Identification: Grommet detection

• Process - Ask Operator to remove grommet from the 40% RSB
  Verification - The fixture should clamp the frame and should not unlock.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-60-10 (60% Rear Seat Back) Error Proofing Identification: Trim & frame

• Process - Ask Operator to scan incorrect trim & frame label for the build label
  Verification - LPS will turn red and will not proceed to next step.

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-80-10 (Rear Cushion Inspection) Error Proofing Identification: Seat must Pass Inspection

• Process - Ask Operator NOT to scan part. Then take it to blind audit to see if it allows them to scan the seat without being scanned in rear inspection
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-80-20 (Rear Back Inspection 60%) Error Proofing Identification: Seat must Pass Inspection

• Process - Ask Operator NOT to scan part. Then take it to blind audit to see if it allows them to scan the seat without being scanned in rear inspection
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-80-30 (Rear Back Inspection 40%) Error Proofing Identification: Seat must Pass Inspection

• Process - Ask Operator NOT to scan part. Then take it to blind audit to see if it allows them to scan the seat without being scanned in rear inspection
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-90-10 (Blind Audit) Error Proofing Identification: Correct seat kit

• Process - Ask Operator to scan a different rear seat kit for front seat build label
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-90-20 (Blind Audit) Error Proofing Identification: Correct seat kit

• Process - Ask Operator to scan a different rear seat kit for front seat build label
  Verification - Screen should turn "red" and the operation should "fail"

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-100-10 Tether Check Error Proofing Identification: 60% RSB Seatbelt check

• Process - Ask operator to not insert the tongue of the 60% RSB into the buckle
  Verification - The Station will not move onto the next step until complete

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-100-10 Tether Check Error Proofing Identification: 60% RSB Tether Check

• Process - Ask operator to not use the tether check machine to verify tether
  Verification - The Station will not move onto the next step until complete

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Station #: S2-100-10 Tether Check Error Proofing Identification: Belly Band verification

• Process - Ask operator to not tap screen to verify belly band is above laser line
  Verification - The Station will not move onto the next step until complete

• Is Lock-out system operable

  Yes

  No

• Is System in Bypass

  Yes

  No

Non - Conformances

• Any Non-Conformances

  Yes

  No

• Station #:

• Issue Description:

• Correction Action:

• Champion:

• Complete:

• Station #:

• Issue Description:

• Correction Action:

• Champion:

• Complete:

• Require additional Fields

  Yes

  No

  N/A

• Station #:

• Issue Description:

• Correction Action:

• Champion:

• Complete:

• Station #:

• Issue Description:

• Correction Action:

• Champion:

• Complete:

• Total number of Non-Conformances Found

• Quality Supervisor

  Sign

• Production Supervisor

  Sign