Appendix E3 PDF

GENERAL MOTORS CORPORATION
WORLDWIDE Appendix E3 – Error Proofing for Product and Process Design
GLOBAL STATEMENT OF REQUIREMENTS
Appendix E3
General Assembly Manufacturing

Requirements
ERROR PROOFING for PRODUCT

and PROCESS DESIGN
Note: This document contains only Sections 4 and 5 of the Error Proofing for
Product and Process design document.
Section 4
The Product / Process Design Matrix
Section 4 in the Error Proofing for Product / Process Design manual
contains the Product / Process Design Matrix. This is an important error
proofing aid that is available for your use when you are researching how
to error proof a part or process.
What the Matrix Contains
A Copy of the Product / Process Design Matrix is shown on the following

page. The Matrix contains three key sections:
• The top row lists the eight potential failure modes that you may be
responding to. One of these eight would have been identified
during a Process Failure Mode and Effects Analysis (PFMEA), by
completing a product or process worksheet for a future vehicle
program, or from problem solving a problem in a current vehicle
program.
• The First Column, on the left side of the Matrix, lists error proofing
guidelines. These guidelines are separated into three groups: one
for the guidelines dealing with design features, another group for
those related to process control, and the final group of guidelines
relates to visual control.
• Cells make up the body of the matrix. Many of them contain

references to examples that are contained in later sections of the
Error Proofing for Product / Process Design Manual. However,
even when the cell is blank, that does not necessarily imply that
the error proofing method does not apply to that failure mode –
just that we do not have an example to reference.
Guide to Using Product/Process Design Matrix
The Y-axis of the Product / Process Design Matrix is divided into three
design/process sections: Design Features, Process Control, and Visual
Control. Design features include guidelines that aid in product assembly.
Process control & visual control sections include guidelines with respect
to process issues.
The X-axis of the matrix is made up of the following potential failure

modes:
• Part installed in wrong orientation: Upside - Down
/ Flipped / Wrong alignment
• Part installed on wrong side (ex. RH on LH)
• Part missing / operation missed
• Wrong part can be installed
• Wrong color
• Part not secured (ex. Wiring harness, fasteners ,snap
fit)
• Correct parts installed in wrong sequence
• Part Damaged
The examples include a write-up of the potential failure modes eliminated,

the work cell before improvement, and the work cell after improvement. At
the bottom of each example sheet, a small box lists the particular check
location, detection method, and feedback type (see descriptions below).
Detection Method Location of Check

Contact/Feature Method: Detects Source: Checks for an error before a
abnormalities in shape or dimension process begins to ensure that only
(size, orientation, etc.) quality parts are being used in the
operation.
Constant Value/number: Detects
abnormalities by checking for a Self: Checks for a defect during a
specified number of motions. process, before sending the job to the
next station.
Action/Motion Step: Detects
abnormalities by checking for a Successive: Check occurs after the
deviation in the required motion or process but before the next process
sequence (e.g. you must do step A begins.
before you do step B.)
Feedback Type
Warning: Informs the operator that an
error or defect has just occurred. Typically
a light (flashing more effective), or audible
alarm.
Halt: The assembly line stops to alert the
operator of the defect. (QAS Line Stop).
Location of Check Detection Method Feedback Type

Source • Contact Warning
Self • Constant Number • Halt •
Successive Action Step •
Product/Process Design Matrix
(1) (2) (3) (4) (5) (6) (7) (8)

FAILURE MODES Parts
Part Part Part Wrong part installed /
DESIGN/PROCESS installed in installed missing - can be secured in
GUIDELINES wrong on wrong operation processed/ Wrong Part not wrong Part
orientation side missed installed Color secured sequence damaged
DESIGN FEATURES
A: Commonize parts including
interface. Reduces complexity of
A2 A3 A4 A5
assembly; Operator Best People
Practices through model mix.
B: Integrate parts for ease of
B3 B6
assembly (Reduce # of parts)
C: Positive Orientation - can be
installed only one way - locating,
C1 C2 C3 C4
alignment, anti-rotational features in
design (tabs, pins, etc.)
D: Design product such that the
successive sequence of assembly D3 D4 D6 D7
will detect error
PROCESS CONTROL - (Controlled by GM-COSS Infrastructure)
E: Install COSS Part Selection Lights E2 E4 E5
F: Install COSS Part Selection

F2 F3 F4 F5 F6 F7
Verification Device
G: Utilize computerized torque
G3 G4 G6 G7
controller
H: Utilize sensor/tool to detect
absence of part, feature of part, color
H1 H2 H3 H4 H5 H6 H7 H8
of part, orientation of part, present
part, cycle counter, etc.
I: Design part to utilize COSS
barcode scanning system after I2 I3 I4 I5
installation.
J: Design electronic module to utilize
serial data communications and
J2 J3 J4
identify through vehicle diagnostics
and/or ALDL test (GATS).
K: Design electronic module to utilize

K4
in-plant programming (GATS).
VISUAL CONTROL
L: Color code part design, manifest
or interfaces (Operator Part L1 L2 L3 L4 L5
Identification System - O.P.I.S.)
M: Positive orientation visual
features indicated on part: matching
M1 M2 M3 M4 M6 M7
features (geometry, arrows, colors)
arrows, wording "FRT", etc. (O.P.I.S.)
N: Positive operator feedback.

Allows for easy inspection at source; N3 N6 N7
visual, audible, tactile
O: "Paint Mark" application with
O3 O6
100% inspection
Design Examples
Ref. Description Section Cross Reference
Section Location
A2 Side Impact Sensing Module Product
A3 Tailgate Hardware Product
A4 Electronic Module Product
A4 Side Impact Sensing Module Product A2
A5 Headliner Product
B3 Inside Rear View Mirror Product
B3 Garnish Moldings Product
B3 Ring Terminal Product
B6 Park Brake Handle Product
B6 Inside Rear View Mirror Product B3
C1 Wire Harness Breakout Product
C1 Door Molding Product
C1 Engine Mounts Product
C1 Rear Side Impact Air Bag Module Product
C2 Engine Mounts Product C1
C2 Rear Side Impact Air Bag Module Product C1
C3 Wire Harness Breakout Product C1
C4 Wire Harness Breakout Product C1
D2 Outside Door Handle Product
D3 Upper Rear Strut Bolt Product
D4 Connector Key Product
D4 Driver Side Air Bag Product
D4 Mass Air Flow Connector Product
D6 Seat Bolt Cover Product
D6 Engine Compartment Lamp Harness Product
D6 Upper Rear Strut Bolt Product D3
D7 Wiper Motor Product
E2 Part Selection Process
E4 Part Selection Process E2
E5 Part Selection Process E2
F2 Part Selection Lights with Verification Process
F3 Part Selection Lights with Verification Process F2
F6 Hose Clamp Process
G3 Torque Tool Process
G4 Torque Tool Process G3
H1 Battery Installation Process
H1 Brake subassembly Process
H2 Door Locks Process
H3 Proximity Button Process
H3 Headlight Adjustment Process
H4 Brake subassembly Process H1
H4 Driver Side Air Bag Process
H4 Wheel Hub Conveyor Process
H5 Driver Side Air Bag Process H4
H6 Brake subassembly Process H1
H6 Torque Fm Tool Process
Design Examples (Contd.)
Ref. Description Section Cross Reference

Section Location
H7 Tire Lug Nuts Process
H8 AC Deflector Vent Process
I2 VCVS Process
I3 VCVS Process I2
I4 Driver Side Air Bag Process H4
I4 VCVS Process I2
I5 Driver Side Air Bag Process H4
J2 Electronic Module/Serial Process
J3 Electronic Module/Serial Process J2
J4 Electronic Module/Serial Process J2
K4 Electronic Module Product A4
L1 Instrument Panel Harness Process
L1 Lock Rod Visual
L2 Door Handle Visual
L2 Door Hardware Visual
L3 Door Nut Visual
L3 Brake Washer Visual
L3 SIR Connection Visual
L4 Color Manifest Visual
L4 Driver Side Air Bag Product D4
L4 Lock Rod Visual L1
L4 Manifest Visual
L4 Manifest Plate Visual
L4 Radiator Hose Visual
L4 Window Regulator Visual
L4 Spring Visual
L5 Manifest Visual L4
M1 Battery Cable Conduit Visual
M1 Door Molding Product C1
M1 Mass Air Flow Visual
M1 Radiator Clip Visual
M1 Radiator Hose Visual L4
M1 Rear Side Impact Air Bag Module Product C1
M2 Door Handle Visual L2
M3 Brake Washer Visual L3
M4 Matching Visual
M6 Radiator Hose Visual L4
N3 Fastener Visual
N6 Seat Bolt Cover Product D6
O3 Cotter key Visual
O6 Battery Paint Visual
O6 Paint-mark Visual
O6 Torque Wheel Visual
Design Feature Examples

Side Impact Sensing Module A2, A4
Failure Mode Addressed: Side Impact Sensing Module (SISM) could be
installed on wrong side of vehicle or wrong part
could be processed/installed.
Before Improvement: Part selection is based on part features.
After Improvement: SISM functionality is independent of orientation in

180 degree plane and symmetric around centerline.
This allows the module to be mounted on both the
left and right hand sides of the vehicle; hence the
operation does not require multiple parts to choose
from.

Source • Contact • Warning
Self Constant Number Halt •
Successive Action Step
Tailgate Hardware A3
Failure Mode Addressed: Tailgate hardware could be installed improperly with
parts missing.
Before Improvement: Too many parts required in the tailgate assembly

process often results in improper installation with
parts missing.
After Improvement: Tailgate hardware has only one fastener instead of

three. It consists of only one part.
After
Before

SHREVEPORT
Electronic Module A4, K4

Failure Mode Addressed: Wrong electronic module could be installed.
Before Improvement: Part selection is based on the vehicle manifest

data.
After Improvement: A common electronic module was developed which

incorporated many different applications within
same software set with calibration differentiating
applications. Minimizing the number of parts
reduces the chance of error. A special
computerized tool identifies the vehicle in station
and downloads the calibration software to the
electronic module through on-line flash
programming equipment and verifies the electronic
module. It is tied to COSS System to ensure correct
build in station.

TRUCK PCM
Headliner A5
Failure Mode Addressed: The wrong color headliner could be installed.
Before Improvement: Typically there are many color choices of

headliners. For example, tan and gray headliners
can easily be confused.
After Improvement: The U-Van only offers a gray headliner so there is

never a wrong color headliner installed.

Inside Rear View Mirror B3, B6

Failure Mode Addressed: The inside rear view mirror screw could be missing
or not properly secured.
Before Improvement: The rearview mirror is installed and secured with a

screw, and sometimes it may not be secured and is
difficult to detect in the plant.
After Improvement: The new design of the inside rear view mirror is
snap fit and does not require a fastener to secure it.
Before After

MORAINE, LINDEN, SHREVEPORT
Garnish Moldings B3
Failure Mode Addressed: Garnish molding can be installed with screws
missing.
Before Improvement: Fasteners were separate parts and not integrated to

the main part; creating the possibility for some to go
uninstalled.
After Improvement: Threaded fasteners were replaced with integral

fasteners. This reduced the total part count from
ten parts to two.
Before After

MORAINE, LINDEN
Ring Terminal B3
Failure Mode Addressed: Ring terminal grounding installation missed.
Before Improvement: Multiple grounds secured at one location or operation. Operator

had to ensure correct number of grounds were secure.
After Improvement: Welding ring terminals together prevents the operator from missing
a terminal by integrating them. Welded ring terminals was a first
step towards splice packs (another means of integrating grounds.)

1997 BUICK PARK AVE
23
Error Proofing for Product & Process Design - Reference Manual

QN-1156, September 2001 © 2000, General Motors Corp., All Rights Reserved
Park Brake Handle B6

Failure Mode Addressed: The park brake handle may not be properly secured.
Before Improvement: It is difficult to detect if the fastener is properly secured.
After Improvement: The new design of the park brake handle assembly is snap fit and
does not require any fasteners to secure it.
Before
After

MORAINE, LINDEN, SHREVEPORT
24

Wire Harness Breakout C1, C3, C4

Failure Mode Addressed: Wire harness may not be installed in correct
orientation or connection may not be made if harness breakout is not in
correct position.
Before Improvement: Wire harness leads break out at one location. Wire harness breakouts
could be not orientated properly
for corresponding connections. Operators may have
to untwist harness leads and determine correct lead
for their operation. Wires may be pinched or wrong connections made if
the harness is not in the correct orientation.
After Improvement: The 1997 Buick Park Avenue wiring harness design staggered these
breakouts, positively locating the
wiring pigtails for each connection, so that harness
was orientated in proper position reducing the
probability of pinched wires and missed or wrong connections.

Source • Contact • Warning •
Self Constant Number Halt
1997 BUICK PARK AVENUE
25

Door Molding C1, M1

Failure Mode Addressed: The molding could be installed in wrong orientation.
Before Improvement: Correct orientation of the molding is identified on the pad document.
It is based on visual appearance and requires training to identify it
correctly.
After Improvement: Correct orientation was accomplished by offsetting the spacing of

one of the attachment clips and subsequently offsetting the spacing
of the pierced holes in the door panel. Additionally, the lead clip
was color coded as a visual aid to the operator.

Source Contact • Warning
Self • Constant Number Halt •
NUMMI
26

Engine Mounts C1, C2

Failure Mode Addressed: The engine mounts installed in the wrong orientation
or on the wrong side.
Before Improvement: The engine mounts were installed to the frame with a specific left and
right hand engine mount. There were common holes on the frame to
which the engine
mounts were assembled. These common holes
allowed for the wrong orientation of the engine mount
to the frame. This error was not detected until engine
set which was much farther along in the operations.
Each error generated a considerable amount of repair.
After Improvement: The engine mounts were designed with tabs, which fit
into slots instead of having the generic bolt holes.
These tabs and slots are placed on one side of the
engine mount and frame. Consequently, this design
will not allow the engine mounts to be installed in the wrong orientation or
the wrong side.

WENTZVILLE
27

Rear Side Impact Air Bag Module C1, C2, M1

Failure Mode Addressed: Rear Side Impact Air Bag (RSIAB) module could be installed upside
down or LH and RH could be interchanged and installed.
Before Improvement: RSIAB was an “off the shelf” part designed by the supplier. RSIAB
bracket fit over two quickie studs mounted in keyhole slots on rear
quarter center inner and is secured with two nuts. Symmetry in the
RSIAB bracket allowed for the incorrect mounting of the module
(upside down and LH/RH parts interchanged).
After Improvement: RSIAB brackets were changed to eliminate incorrect installation.

Lower attachment surface was lengthened to provide an interference
with the rear quarter center inner if installed upside down.
Attachment holes were off center to eliminate the LH and RH sides
from being switched and installed. “UP” and arrow embossed on
part to assist operator in identifying correct part orientation. For
packaging reasons, bracket-mounting location was moved to body
side ring.

DETROIT, HAMTRAMCK
28

Upper Rear Strut Bolt D3, D6

Failure Mode Addressed: The upper rear strut bolt could be missed or not properly secured.
Before Improvement: The upper rear strut bolt is secured and a decorative plastic cap is
placed over the top of the strut bolt to conceal it from the interior
compartment of the vehicle. The plastic cap is a snap fit design and
is snapped into pierced holes in the rear shelf sheet metal. The
problem is that occasionally, the rear strut bolt does not get fully
secured due to cross threading and the cap gets installed, covering
the defect from visual inspection.
After Improvement: Redesign the decorative plastic cap so that it is still a snap fit,
however, it is snapped onto the rear strut bolt in conjunction with a
single pierced hole in the rear shelf. In the event that the rear strut
bolt is missed or not properly secured, the cap will not snap onto the
bolt and into the pierced hole

Successive • Action Step
NUMMI
29

Connector Key D4
Failure Mode Addressed: Incorrect Supplemental Inflatable Restraint (SIR) Sensing/Diagnostic
Module (SDM) could be installed
in vehicle.
Before Improvement: Wrong SDM could be installed in vehicle and not

caught until final electrical check.
After Improvement: By incorporating mechanical keying into a “nose

piece” that is part of the SDM electrical connection,
the SDM could not be connected electrically if the
wrong part was installed. Incorporating this error
proofing guideline reduces waste. Special note: Connector keying is an
effective means for preventing
the customer from getting a misbuilt vehicle.
However, connector keying proliferates parts on both
the component and corresponding harness sides
(in this case an additional nosepiece was added to harness). In most
cases, it is recommended that an electronic module be common (A4) or a
part selection
bin and serial data keying (F4 with K4) be
incorporated to reduce the probability of selecting the wrong part and
prevent a defect from getting out of the assembly plant.

1997 BUICK PARK AVE
30

Mass Air Flow Connector D4

Failure Mode Addressed: Wrong Mass AirFlow (MAF) could be installed during bench
subassembly.
Before Improvement: There are two MAF sensors: 2 wheel drive and 4 wheel drive. The
MAF sensor and ducting are sub-assembled off line and sequenced
for delivery to the main line. A wrong MAF sensor installed in a
subassembly may not be detected until DVT or emissions testing
therefore requiring end of line repair.
After Improvement: The MAF sensor electrical connection is larger on 4 wheel drive
sensors. This assists in the selection of the correct sensor for
installation. If the wrong MAF sensor is installed in the
subassembly, the main line operator is unable to connect the wiring
harness allowing the error to be detected and corrected in station on
the main line. Note: This did not pro life rate the engine
compartment wiring harness because the 2 and 4 wheel drive
harnesses are unique.

NUMMI
31

Engine Compartment Lamp Harness D6

Failure Mode Addressed: Engine compartment forward lamp harness to body
harness connection may not be fully seated.
Before Improvement: Engine compartment forward lamp harness to body harness

connection may not be fully seated. No feedback was available to
the operator if this occurred.
After Improvement: The 1997 Buick Park Avenue design utilizes a Connector Positive
Assurance (CPA) on a rope as a successive operation to ensure
that the connection is fully seated. The CPA cannot physically be
installed unless the connection is fully seated. Provides immediate
feedback to operator if not fully seated. Once connection is fully
seated connector is designed not to unseat.

Source Contact Warning •
Successive • Action Step •
1997 BUICK PARK AVE
32

Seat Bolt Cover D6, N6

Failure Mode Addressed:The seat bolt and seat bolt cover may not be securely installed.
Before Improvement: The seat bolt may not be securely installed and may not be detected
in the plant. It is critical that the seat bolt be secure. Also, if the seat
bolt is not secure, the seat bolt cover will not fit securely.
After Improvement: The seat bolt cover has ribs that will not allow the cover to be
installed if the seat bolt is not properly secured. If the bolt is
secured, the seat bolt cover will produce a “snap” sound as it is
properly placed.

NUMMI
33

Wiper Motor D7
Failure Mode Addressed: Correct part could be installed in wrong sequence.
Before Improvement: The windshield wiper motor is installed over a weld stud in the
motor compartment. However, prior to installing the wiper motor, a
ground terminal must be placed over the weld stud, which is then
captured by the wiper motor housing. In some cases, the wiper
motor inadvertently gets installed prior to the ground terminal.
After Improvement: Design the weld stud with a shoulder at the base and design the
ground terminal to act as a spacer between the motor compartment
wall and the wiper motor housing. If the ground terminal is not
installed, the wiper motor will not secure even when the nut is fully
tightened. This is easily noticeable.

Source Contact • Warning •
Self • Constant Number Halt
NAO – GAC
34

Process Feature Examples

Part Selection E2, E4, E5
Failure Mode Addressed: Installation of wrong part or wrong color.
Before Improvement: Part selection is based on option build code data on the vehicle
manifest. The wrong part could be selected.
After Improvement: Part selection lights installed over part containers prompt the
operator to pick/select correct part and install on the vehicle. The
part selection lights are driven by NAVO “COSS” System described
elsewhere in this manual. For more information on NAVO common
part selection devices, refer to Part Selection section of the manual.

Source • Contact Warning •
Self Constant Number • Halt •
PONTIAC EAST
35

Part Selection Lights with Verification F2, F3, F4, F5, F7

Failure Mode Addressed: Installation of wrong part, wrong color, and operation
not completed or correct parts installed in wrong sequence.
Before Improvement: Part selection is based on option build code data on the vehicle
manifest. The wrong part could be selected.
After Improvement: Part selection lights with verification or light curtains installed over part
containers identify the correct
parts to select and install on the vehicle. The “COSS” error-proofing
system drives the part selection lights/
light curtains on the parts. The light curtain/ sensors
verify that the correct part was selected. Selecting the wrong part will
activate an audible warning alarm. It
is tied to Quality Andon System to ensure a correct
build in station. For more information on NAVO
common part selection devices reference Section 8.

NUMMI
36

Hose Clamp F6
Failure Mode Addressed: The hose clamp may not be secured.
Before Improvement: Based on the option build code of the vehicle

manifest, a hose retaining clip is removed allowing
the clip to spring and secure the hose. This operation
can be missed on low production build options.
After Improvement: Part selection with verification was utilized. A light

curtain was installed over the dunnage waste
container to ensure the retaining clip had been
removed from the hose retainer. If the light beam
is not broken, the line will be stopped at the Fixed
Position Stop, by the “COSS” System. For more information on NAVO
common part selection devices, reference the part selection section.

37

Torque Tool G3, G4, G6, G7

Failure Mode Addressed: Installation of wrong part, operation not completed,
part not secured or correct parts installed in wrong sequence.
Before Improvement: Part selection is based on option build code data

from the vehicle manifest. Correct torque is
dependent on the tool and verified by the operator.
After Improvement: The NAVO “COSS” system interfaces to each of the Fastening
Controllers. If the correct torque achieved/ Cycle complete is
not received by the “COSS” system a QAS line stop is initiated
in the footprint to ensure correct build in station. Refer to torque
repair flow chart in section B-4 of this manual.

PONTIAC EAST
38

Battery Installation H1
Failure Mode Addressed: The battery could be installed in wrong orientation.
Before Improvement: A robot does the installation of the battery. It was possible to load the
battery in the wrong orientation.
Not detecting the correct orientation of the battery,
the robot installs the battery into the vehicle with the battery terminals
on the wrong side.
After Improvement: Guide rollers with plates were installed on the roller
rack to prevent incorrect battery load.
Incorrect Orientation Correct Orientation

NUMMI
39

Brake Sub-assembly H1, H4, H6

Failure Mode Addressed: The fuel and brake line bundle may not have the proper parts
installed, and/or not be properly secured, and/or parts installed in
the wrong orientation.
Before Improvement: Based on job instructions and training, the parts are visually
inspected and installed in the correct orientation.
After Improvement: A fixture was designed so that parts could only be installed in the
correct orientation. Controls were utilized to interlock clamps, which
held the fuel and brake lines and would not release until the fuel
filter was installed and properly secured.

Source Contact Warning
NUMMI
40

Door Locks H2
Failure Mode Addressed: The door locks or housing parts could be installed on the wrong
side.
Before Improvement: At the subassembly of the door locks and door rods, there was a
problem with installing the wrong side door rod or door lock to the
housing. This is a subassembly operation in which both sides of the
door locks, housings, and rods are assembled at the same station.
The similarity of the parts created a risk of error.
After Improvement: The plant installed special tabs on the fixture, which sub-assembles
the door lock to the housing. This will not allow the wrong side door
lock to be assembled to the wrong side housing. The door rods and
fixtures were also color coded to correspond to the right and left
hand parts. This has eliminated the problem of installing the wrong
side door lock to the wrong side housing.

WENTZVILLE
41

Proximity Button H3
Failure Mode Addressed: The operation of securing the radiator hose can be missed.
Before Improvement: There were no visual controls to indicate an unsecured hose.
After Improvement: A proximity button was installed on the operator’s tool pedestal. If
the operator does not pick up the tool to secure radiator hose
clamps, an alarm sounds then the line stops. It is tied to the Quality
Andon System to ensure correct build in station.

NUMMI
42

Headlight Adjustment H3
Failure Mode Addressed: The headlight adjustment could be missed.
Before Improvement: The headlight adjustment could be aligned wrong

before the vehicle was released to the next station.
After Improvement: The plant installed a barricade, which acts as a door

in front of the vehicle. As the vehicle pulls into the headlight adjustment
station, the door has visual
crosses, which aids the operator to correctly adjust
the headlight aim. Once headlights are adjusted correctly, a sensor
recognizes proper headlight aim
and allows the door to open. If the headlights are not properly aimed,
the door will not open, and the
vehicle will have to stay in the station until it is
corrected.

43

NUMMI
Driver Side Air Bag H4, H5, I4, I5

Failure Mode Addressed: The wrong model or color of driver side air bag could
be installed.
Before Improvement: Part selection was based on the option build code
data of the vehicle manifest.
After Improvement: The operator scans the bar code on the manifest to
identify the vehicle in station. Driver side air bag
containers are placed line side in automatically
controlled drawers that open to present only the model
and color required. The operator scans the bar code
located on the part to verify part selection and collect
traceable data.

44


NUMMI
Brake Drum Conveyor H4
Failure Mode Addressed: The wrong wheel hub could be installed.
Before Improvement: There are two types of wheel hubs to choose from and they look
similar; 2WD and 4WD. If the material were placed in the wrong
rack it may not be noticed.
After Improvement: Roller conveyors with different widths were added for 2WD and
4WD wheel hubs. The 4WD-wheel hub would not fit on the narrower
2WD conveyor when parts were loaded on the conveyor. 2WD parts
can be loaded onto the 4WD conveyor; however, they can be easily
distinguished by excess space around the smaller hub.

45

NUMMI
Torque FM Tool H7
Failure Mode Addressed: Part may not be secured.
Before Improvement: No alarms or lights on the tools to indicate proper torque was
obtained.
After Improvement: The RF torque wrench sends a signal to the “COSS” system. If
torque is not reached on three critical fasteners, sending three
signals, an alarm sounds, and a QAS line stop is initiated. It
ensures correct build in station.

46


NUMMI
Tire Lug Nuts H7

Failure Mode Addressed: Tire lug nuts could be secured in the wrong sequence.
Before Improvement: The tire lug nuts were required to be tightened in a specified
sequence. Using a single spindle tool does not ensure the
tightening sequence is being followed.
After Improvement: A multiple spindle gun with torque control is used instead of the
single spindle gun. The multiple spindle guns tightens the lug nuts
in a specified sequence. Torque is monitored as the lug nuts are
secured. It is tied to the “COSS” System to ensure correct build in
station.

47


AC Deflector Vent H8
Failure Mode Addressed: The A/C deflector vent could be damaged during installation.
Before Improvement: The A/C deflector vent is installed by hand. This part is difficult to
install and if the operator inadvertently applies excessive force or
side load to the part during installation, the part becomes damaged.
After Improvement: A simple hand tool was designed to evenly distribute the insertion
force over the entire front surface of the part and aid in guiding the
part into the opening without generating additional side loads.
48


DETROIT HAMTRAMCK
VCVS I2, I3, I4

Failure Mode Addressed: Installation of wrong part or operation not completed.
Before Improvement: Part selection is based on the option build code data on the vehicle
manifest.
After Improvement: “COSS” is being implemented to identify the vehicle coming into
station. Vehicle ID input into VCVS system prompts the operator to
scan the bar-code label of the correct part. Bar code scanning is
done to collect required traceable data for a vehicle and to verify
that the correct part is installed. If the correct operation were not
performed during the operation cycle time, a VCVS/Footprint QAS
line Stop is initiated. It is tied to the “COSS” System to ensure
correct build in station.
49


PONTIAC EAST
Electronic Module/Serial J2, J3, J4
Failure Mode Addressed: The wrong electronic module could be installed.
Before Improvement: Part selection is based on the option build code data on the vehicle
manifest.
After Improvement: Electrical tester can verify electronic modules are correct based on
vehicle options through serial data communications. Electronic
modules can sense an open circuit in case a component is not
installed. Electronic module will set a malfunction code that will be
picked up by vehicle diagnostics end of line ALDL Static/Dynamic
vehicle test tied to Quality Gate Hold system.
50


PONTIAC EAST
Instrument Panel Harness L1

Failure Mode Addressed: Instrument Panel harness could be installed in wrong orientation.
Before Improvement: Routing of the IP harness breakouts were not always obvious and
connections could be made to the wrong adjoining components.
After Improvement: The 1997 Buick Park Avenue design utilizes extensive color coding
in this area to assist the operator to successfully complete the
operation. Wires that go up for corresponding connection are purple;
lime green wires go down. Pink wires pass through the IP retainer;
black wires pass through the magnesium beam. The colored tape
provides a means to quickly deter mine the proper orientation of
each IP wiring harness breakout, and reduces waste and risk of
errors. Note: The 1997 Buick Park Avenue followed a modified
Operator Parts Identification System (O.P.I.S.) due to conflicts with
previous plant practices and availability of colored tapes. However,
in the future, with flexible manufacturing assembly plants building
many different GM products, it will become critical that all plants
utilize a common color coding system such as OPIS. When using
color coding, reference the O.P.I.S. guidelines included in this
manual (section A8).

51


1997 BUICK PARK AVE
Visual Control Examples

Lock Rod
Failure Mode Addressed: Lock rod could be installed in wrong orientation or
could be installed on wrong side.
Before Improvement: The operator visually inspects the part and based on
prior training of the part design and its proper
assembly orientation, installs the appropriate rod
end to the door latch. In a successive down-line
station, a second operator connects the other end of
the rod to the door handle.
After Improvement: Each lock rod assembly is color coded at the end that connects
to the door handle. Also, the lock that connects to the top of the
door handle has one stripe on it. The lock rod that connects to the
bottom of the door handle has two stripes on it. Finally, the stripes
on the lock rods are color coded for each side of the vehicle. The
left lock rods have red paint stripes and the right lock rods have
green paint stripes, which are the proper Operator Part
Identification System (OPIS) colors. When using color-coding,
reference the O.P.I.S. guidelines included in this manual. The lock
rod assembly fixture has an instruction plate with a color illustration
indicating proper orientation.
52


FAIRFAX
Door Handle L2, M2

Failure Mode Addressed: The outside door handle could be installed on the wrong side.
Before Improvement: The outside door handle for the left hand and right hand parts
looked similar.
After Improvement: The outside door handles are color keyed for left hand versus right
hand. The left handle has a yellow plastic part and the right handle
has a white plastic part. The handles are also stamped with LH &
RH. When using color to identify specific parts, reference the
O.P.I.S. guidelines included in Section A4.
53


NUMMI
Door Hardware L2
Failure Mode Addressed: Incorrect rear door hardware module could be selected for installation.
Before Improvement: Left and right rear door hardware modules are mirror images of each other and
are sometimes difficult to distinguish.
After Improvement: The 1997 Buick Park Avenue rear door hardware modules utilize color-
coding to assist operator in selecting the correct assembly. The rear door
hardware module with blue tape is used on the left door. The right hand
door uses lime green tape. The colored tape provides a means to quickly
determine the correct 54rear door hardware module, which reduces waste.
Note: The 1997 Buick Park Avenue followed a modified

Operator Parts Identification System (O.P.I.S.) system due to previous
plant practices and availability of color- red tapes. However, in the future,
with flexible manufacturing assembly plants building many different GM
products, it will become critical that all plants utilize a common color-
coding system such as OPIS. When using color-coding, reference the
O.P.I.S. guidelines included in Section A4.

1997 BUICK PARK AVE
Door Nut
Failure Mode Addressed: The push nuts or screws could be missing.
Before Improvement: Push nuts are typically white or black. White push nuts are difficult
to detect on white and light colored vehicles and black push nuts
are difficult to detect on black and dark colored vehicles.
After Improvement: The push nuts are bright yellow, which are easy to detect on all
vehicle colors. The next operator installs a bracket that covers all
four-push nuts and 55secures it with four screws. The bright yellow
push nuts provide a better visual alignment of the large bracket

since the bright yellow is more noticeable through the holes in the
bracket. If this bracket is not installed with all four screws, then the
bright yellow showing through the hole in the bracket allows for easy
detection of a missing screw.

NUMMI
Brake Washer L3, M3

Failure Mode Addressed: The brake washer and bolt assembly could be built with no washer
or multiple washers. It is critical that one and only washer be
installed to prevent leaks.
Before Improvement: A regular washer is difficult to see once the bolt is secured. It is
difficult to detect whether no washer, one washer, or multiple
washers have been installed.
56

After Improvement: The brake washer and bolt are both a copper color and visually
stand out. The washer has 3 tabs that extend past the head of the
bolt. The 3 tabs protruding from the washer allow for easy visual
verification that one and only one washer have been installed. If
multiple washers were installed more than 3 tabs would extend past
the head of the washer.

NUMMI
SIR Connection
Failure Mode Addressed: Supplemental Inflatable Restraint (SIR) connection
could be missed.
Before Improvement: Operation and subsequent inspection of safety

system are not always obvious as to which
connection to make or whether connection was made.
57

After Improvement: A common color-coding, (yellow) was utilized for all

SIR leads and their connections. This assists both
repair and assembly in making connections and
provides for ease of inspection. NAO common color coding of the SIR
system and the special precautions
that should be taken with the yellow colored wiring
and connections provides a common language
throughout GM assembly plants and dealer repair shops.

1997 BUICK PARK
Color Manifest L4
Failure Mode Addressed: Wrong parts could be processed or installed.
Before Improvement: Since there is a significant way to identify an export or special order
job, selection of the wrong part could occur.
After Improvement: Color manifest for 58exports and special orders were used to
provide a visual signal.

NUMMI
Manifest L4, L5
Failure Mode Addressed: The wrong part could be installed.
Before Improvement: Part selection is based on option build codes on the vehicle manifest.
Many option build codes were very similar.
59
After Improvement: Colored blocks on the manifest allow for easy identification of the
necessary information (part #’s or option build codes.)

NUMMI
Manifest Plate L4
Failure Mode Addressed: The wrong part could be installed.
Before Improvement: Part selection is based on numerical code on the vehicle manifest.
After Improvement: The manifest is fed through a cover plate with openings, which
60
allow for better legibility. The cover plate masks unwanted
information.

NUMMI
Radiator Hose L4, M1, M6

Failure Mode Addressed: Wrong radiator hose could be installed, correct hose could be
installed in the wrong orientation, or hose may not be properly
secured.
61
Before Improvement: Several different hoses are available for selection
and the hoses can also be installed in the wrong orientation. In

addition, if the clamp is not placed properly, the hose will not be
secured. Detection of these defects is difficult.
After Improvement: Each radiator hose is identified with a colored paint

line at each end. The manifest identifies the hose by the color. For
example, if the paint marks were white, then the manifest would have
“W” instead of an option build code or part number. (When using color
to identify specific parts reference the O.P.I.S. guidelines included in
this manual.) The paint lines on the hose also indicate which side of
the hose is the topside. The words on the hose identify the
correct orientation. The length of the paint lines also marks the area
that clamps have to be placed to be properly secured. The clamps
must be placed within the length of the colored line.

NUMMI
Window Regulator L4
Failure Mode Addressed: The wrong window regulator could be installed.
Before Improvement: There are two different window regulators to choose from and they
look identical. If the material is placed in the wrong place it may not
be noticed. 62

After Improvement: Each different window regulator has a different colored roller for
identification. The manifest identifies the window regulator by the
color of the roller. For example, if the roller were green then the
manifest would have a “G” instead of an option build code or part
number. When using color to identify brand specific parts reference
O.P.I.S. guidelines included in this manual.

NUMMI
Spring L4
Failure Mode Addressed: Wrong spring could be installed.
Before Improvement: Multiple springs to chose from and all of the springs
look identical. If the material is placed in the wrong
area of the material 63rack, it may not be recognized.
After Improvement: Each different spring has a different colored paint

mark to identify it. The material rack is painted on the front and back to
correspond to the paint mark on the spring. These improvements in
visual controls will assist both the material and line operators. The
manifest identifies the required spring by the color of the paint mark.
For example, if the spring were to be painted with a red mark then the
manifest would have an “R” instead of an option build code or part
number. When using paint marks on parts reference the O.P.I.S.
guidelines included in this manual.

NUMMI
Battery Cable Conduit M1

Failure Mode Addressed: Battery cable conduit could be clipped in wrong
location, therefore installing part in wrong orientation.
Before Improvement: Battery cable conduit could be orientated improperly

due to location of 64clip. Proper clip location prevented battery cable
from contacting accessory drive belt.
After Improvement: Conduit has white tape in the critical area designating proper clip
location to prevent the battery cable from contacting the accessory
drive belt.

1997 BUICK PARK AVE
Mass Air Flow M1

Failure Mode Addressed: Mass airflow duct could be aligned wrong during bench assembly.
Before Improvement: The Mass airflow duct and sensor are sub-assembled off line and
sequenced for 65delivery to the main line. A misalignment of

the sub-assembly results in installation difficulties on the main line.
After Improvement: An arrow along with the words “AIR FLOW” is stamped into the mass
Air Flow sensor housing, which aligns to a notch in the duct. This
visual aid assists the subassembly operation during the process and
confirms proper alignment.

NUMMI
Radiator Clip M1
Failure Mode Addressed: Wiring harness in the center lower radiator support
area could be 66
routed incorrectly.

Before Improvement: Wire harness conduit could be routed incorrectly due

to starting the first clip in the wrong location.
After Improvement: Conduit has white tape at the first clip to be installed indicating the
starting point for routing the harness in the center lower radiator
support area. The white tape provides the operator with a visual
aid identifying the starting point of the conduit routing, to insure
positive orientation and repeatable builds.

1997 BUICK PARK AVE
Matching M4
Failure Mode Addressed: IP electrical center or Bussed Electrical Center (B.E.C) connections
could be installed 67to wrong location.
Before Improvement: Five electrical connections were made to B.E.C module; two on the
top and three on the bottom. Connections were the same size and
mechanically error proofed so they could not physically be installed.
There was not, however, any visual identification to allow correct
connections except by “trial and error” method.
After Improvement: The five electrical connections to the B.E.C were

labeled with features that matched their corresponding “home” in
the B.E.C housing. These features included matching colors,
numbers, symbols and bar codes besides the fact that they were
still mechanically keyed.

1997 BUICK PARK AVE
Fastener N3
Failure Mode Addressed: Fasteners may not be installed.
Before Improvement: Typically fasteners 68are untreated metal or painted

black. This makes it difficult to identify a missing or

loose fastener against the black chassis through
visual inspection.
After Improvement: Silver and bronze colored fasteners contrast the

typically black chassis. The visual aid assists in the installation of the
fastener as well as verification of fastener presence.

NUMMI
Cotter Key O3
Failure Mode Addressed: Cotter key may not be installed or missing.
Before Improvement: The castle nut was secured and then a cotter key was installed on
69
the part. Due to the black on black finish, it was difficult to
visually inspect.
After Improvement: A “Paint Mark” application with 100% inspection was implemented.
The paint mark made it easier to visually inspect the part to ensure
that the castle nut was properly installed and the cotter key was in
place.

NUMMI
Battery Paint O6
Failure Mode Addressed: Battery cable may not be properly secured.
Before Improvement: Battery cable torque not always torque monitored.

No visual 70inspections to insure torque monitoring on 100% of

vehicles.
After Improvement: Operator monitoring battery cable torque applies

paint marks on the Bussed Electrical Center (B.E.C.) indicating
torque readings have been checked. White and yellow marks
indicate the first shift has checked battery torque. White and green
marks indicate second shift has checked battery cable
torque. These paint marks enable successive visual inspections.

1997 BUICK PARK AVE
Paintmark O6
Failure Mode Addressed: Brake line nuts may not be properly secured.
Before Improvement: The operator manually tightens the brake line nuts with a wrench.
Subsequent 71operators check for specified torque. It is

difficult to visually verify a nut that has received the correct amount
of torque.
After Improvement: Torque is verified with a click wrench dipped in paint that marks the
nut. The paint mark is easily noticed in successive checks to verify
the presence of the paint mark. The absence of the paint mark
triggers a manually initiated Andon signal.

Torque Wheel O6
Failure Mode Addressed: The wheel and tire may not be properly secured.
Before Improvement: The lug nuts are 72secured with a torque controlled
multiple nut runner tied to the Andon line stop. Then the
lug nuts are manually inspected for presence.
After Improvement: When wheel and tire torque is reached, a yellow paint
mark is automatically applied on the tire. The paint
mark is used as a visual aid in manual inspection for
tire and wheel secure, indicating that proper torque
has been reached on all lug nuts.

NUMMI
73

Section 5
Introduction
OPIS (Operator Part Identification System) is a common system adopted by GM as an

inexpensive, first level of Error Proofing of product for low risk situations. (Risk < 75, see
Section 7 for Risk Assessment.) The primary focus of OPIS is to support the operator by
making the selection of the proper part visibly easier. Due to proliferation of option
content, colors, etc. the identification of parts has become very difficult in assembly
areas. For example, left and right door handles look identical at a glance when, in
reality, they are very different. Using OPIS techniques, left and right hand parts can be
easily identified through color coding and labeling. In a similar way, different wiring
harnesses are colored according to their option level so that incorrect harnesses are less
likely to be installed. Many benefits result from this simple coding system. Plants have a
reduced sensitivity to new or changing part numbers, and on-line visual inspections can
be accomplished quickly with better accuracy.
OPIS is broken into five different option classes:

• Truck/Car Line (Chevrolet, Pontiac, etc.)
• Option or Level
• Left/Right
• Front/Rear
• Critical Position
These classifications are described in greater detail on the following pages.
74

OPIS – Division
The following OPIS standard is used for

differentiating parts by division or brand.
Division Letter Color Abbreviation
Chevrolet C Pink CHEV
Pontiac P Purple PONT
Olds O Orange OLDS
Opel OL Green OPEL
Specific
Buick B Blue BU
Cadillac K Yellow CAD
GMC G Gray GMC
Saturn S Red SAT
SAAB SA BROWN SAAB
ISUZU IS White ISUZU
Specialty Triangle Symbol w/ letters

PC
Other
Vehicle (example: PC = Police Car)
Multi Black B
The color can be applied to the part by tape, labels, and letters on labels, components,
or paint marks. Letters should be embossed, stamped or molded.
75

TWO OPTIONS / LEVELS

Option Number Color* Letter
1 None (Base)** None
2 Yellow Y
THREE OR MORE OPTIONS / LEVELS
Option Number Color* Letter
1 Yellow Y
2 Pink P
3 White W
4 Purple P
5 Brown BR
6 Gray GR
7 Blue B
8 Orange O
9 Red R
10 Green G
*Colors used in order of option penetration
**The symbol will represent a base option on the manifest
Note: If more than 10 colors are required, utilize dual colors, striping,
And /or bar codes.
In many cases different vehicle options will require similar, yet different parts. In
these situations you can use standard colors, letters, or numbers to differentiate the
parts for each option. The option on the greatest percentage of vehicles would get
the first color/letter/number (i.e. Yellow/Y/1); the second highest percentage would
get the next color/letter/number, etc.
76

Front or Rear
Use:
RR - or - FRT
If the parts are differentiated by their location on the front or the rear of the vehicle the
following standard should be used. Indicate the front part by the abbreviation “FRT” and
the rear part by the initials “RR”. There are various methods that may be used to affix
the front/rear indications (tape, label, paint, molded, etc.)
77

Left or Right
LH Use: RH
Red - or - Green
OPIS
Parts that are differentiated by their location on the left or right side of the vehicle are
handled similarly to the way front rear parts are. Indicate a left side part by the
abbreviation “LH” and right side parts by “RH”. If these letter designations can not be
used than a fall back color-coding scheme 78can be used. Green indicates right and
Red indicates left.
OPIS – Methods to Identify

Critical Positions
F
R
FRT T
Label Tape
FRT FRT
Paint w/arrow Stam ped
For some parts, the challenge facing the plant operator is how to correctly position it.
OPIS standard methods exist for this situation too. To indicate direction an arrow can
be added indicating the forward or outboard side of the part. Part alignment can be
aided by adding “dots” or “marks” on mating parts.
79

"OPIS" Operator Part Identification System
DIVISION
SPECIALTY
MULTI SPECIFIC
VEHICLE
WHAT
TO USE
WHAT WHAT
TO USE TO USE
TRIANGLE SYMBOL
BLACK/ WITH ABREVIATION
NO COLOR
OR CHEVROLET PONTIAC OLDS OPEL SAAB
"B"
PC PINK PURPLE ORANGE OLIVE BROWN
"C" OR "P" OR "O" OR "OL" OR "SA" OR
"CHEV" "PONT" "OLDS" "OPEL" "SAAB"
PC = POLICE CAR
EX = EXPORT ETC.
METHOD BUICK CADILLAC GMC SATURN ISUZU
BLUE YELLOW GRAY RED WHITE

"B" OR "Y" OR "G" OR "R" OR "IS' OR
"BU" "CAD" "GMC" "S" ISUZU
METHOD
TAPE TAPE
LABELS LABELS
BLACK: LETTERS ON LABELS COLORED: LETTERS ON LABELS
COMPONENTS COMPONENTS
PAINT MARKS PAINT MARKS
EMBOSSED LETTER EMBOSSED

LETTER STAMPED
STAMPED
"B": MOLDED "B": MOLDED
80

81

FRONT / REAR
WHAT TO USE
FRONT REAR
"FRT" "RR"
METHOD METHOD
TAPE WITH "FRT" TAPE WITH "RR"

LABEL WITH "FRT" LABEL WITH "RR"
PAINT "FRT" PAINT "RR"
EMBOSSED "FRT" EMBOSSED "RR"
MOLDED "FRT" MOLDED "RR"
STAMPED "FRT" STAMPED "RR"
ARROW WITH "FRT" ARROW WITH "RR"
USE DIVISION OR OPTION COLORED

"FRT", "RR", AND ARROWS IF NEEDED
82

LEFT / RIGHT
WHAT TO USE
LEFT RIGHT
"LH" "RH"
METHOD METHOD
LABEL WITH "LH" LABEL WITH "RH"

PAINT "LH" PAINT "RH"
EMBOSSED "LH" EMBOSSED "RH"
MOLDED "LH" MOLDED "RH"
STAMPED "LH" STAMPED "RH"
USE DIVISION OR OPTION COLORED

"RH", "LH", AND ARROWS IF NEEDED.
WHEN A LETTER CANNOT BE USED APPLY GREEN COLOR
FOR RIGHT AND RED COLOR FOR LEFT.
WHEN APPLICABLE USE GOLD PLATING FOR LEFT AND
SILVER PLATING FOR RIGHT.
83

Option or Level
TWO OPTIONS / THREE OR MORE

LEVELS OPTIONS / LEVELS
WHAT TO USE WHAT TO USE
COLOR / LETTER
COLOR LETTER NUMBER
IN ORDER OF IN ORDER OF IN ORDER OF IN ORDER OF

USAGE USAGE ** USAGE ** USAGE **
1. NO COLOR/LETTER
(BASE) * 1. YELLOW 1. Y 1
2. YELLOW OR "Y" 2. PINK 2. P 2
(OPTION/LEVEL)
3. WHITE 3. W 3
4. PURPLE 4. PU 4
5. BROWN 5. BR 5
6. GRAY 6. GR 6
METHOD 7. BLUE 7. B 7
8. ORANGE 8. O 8
9. GREEN 9. G 9
COLORED: 10. RED 10. R 10
TAPE
LABELS
LETTERS ON LABELS
COMPONENTS
PAINT MARKS
METHOD METHOD METHOD
NON COLOR: COLORED:

EMBOSSED TAPE LABELWITH LABELWITH
STAMPED LABELS LETTER NUMBER
MOLDED LETTERS ON PAINT LETTER PAINT NUMBER
LABELS EMBOSSED LETTER EMBOSSED
COMPONENTS STAMPED LETTER NUMBER
*THE SYMBOL WILL REPRESENT A PAINT MARKS MOLDED LETTER STAMPED
BASE OPTION ON THEMANIFEST. NUMBER
MOLDED
** COLORS USED IN ORDER OF NUMBER
OPTION PENETRATION.
NOTE: IF MORE THAN (11) COLORS ARE REQUIRED, NOTE: ELECTRICAL USAGE OF YELLOW
UTILIZE DUAL COLORS STRIPING AND/OR BAR CODES RESTRICTED TO S.I.R. ONLY
84


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GENERAL MOTORS CORPORATION

WORLDWIDE Appendix E3 – Error Proofing for Product and Process Design

GLOBAL STATEMENT OF REQUIREMENTS

General Assembly Manufacturing

ERROR PROOFING for PRODUCT

GLOBAL STATEMENT OF REQUIREMENTS

What the Matrix Contains

A Copy of the Product / Process Design Matrix is shown on the following

• Cells make up the body of the matrix. Many of them contain

Guide to Using Product/Process Design Matrix

GLOBAL STATEMENT OF REQUIREMENTS

The X-axis of the matrix is made up of the following potential failure

GLOBAL STATEMENT OF REQUIREMENTS

The examples include a write-up of the potential failure modes eliminated,

Detection Method Location of Check

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Product/Process Design Matrix

(1) (2) (3) (4) (5) (6) (7) (8)

E: Install COSS Part Selection Lights E2 E4 E5

F: Install COSS Part Selection

K: Design electronic module to utilize

N: Positive operator feedback.

GLOBAL STATEMENT OF REQUIREMENTS

GLOBAL STATEMENT OF REQUIREMENTS

Design Examples (Contd.)

Ref. Description Section Cross Reference

GLOBAL STATEMENT OF REQUIREMENTS

Design Feature Examples

Before Improvement: Part selection is based on part features.

After Improvement: SISM functionality is independent of orientation in

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Before Improvement: Too many parts required in the tailgate assembly

After Improvement: Tailgate hardware has only one fastener instead of

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Electronic Module A4, K4

Before Improvement: Part selection is based on the vehicle manifest

After Improvement: A common electronic module was developed which

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Before Improvement: Typically there are many color choices of

After Improvement: The U-Van only offers a gray headliner so there is

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Inside Rear View Mirror B3, B6

Before Improvement: The rearview mirror is installed and secured with a

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Before Improvement: Fasteners were separate parts and not integrated to

After Improvement: Threaded fasteners were replaced with integral

Location of Check Detection Method Feedback Type

GLOBAL STATEMENT OF REQUIREMENTS

Before Improvement: Multiple grounds secured at one location or operation. Operator

Location of Check Detection Method Feedback Type

Error Proofing for Product & Process Design - Reference Manual

GLOBAL STATEMENT OF REQUIREMENTS

Park Brake Handle B6

Before Improvement: It is difficult to detect if the fastener is properly secured.

Location of Check Detection Method Feedback Type

Error Proofing for Product & Process Design - Reference Manual

GLOBAL STATEMENT OF REQUIREMENTS