Action

Check Raw Material Inventory Availability

Discuss with Oscar hire new welder for second shift
Confirm Shipping and Packaging Instructions with Customer
Generate the List of contact between both Plants
Confirm PPAP's Approval
Define Tack Time, Lay Out and Manufacturing Flow Chart
* Implementation plan for Lay-Out
* Modify Welding Bracket Fixture
* Generate the Training Matrix
* Generate TPM's and PM's forms
Generate the consumables List for Spare Parts
* Implement Traning Matrix into the QS
Training Plan for QA Inspectors
* Elaborate WI's for the Manufacturing Process
* Development the PFMEA
* Fabricate Cutting Fixture
* Fabricate Cutting and Welding Booth Stations
* Fabricate and Validate GO/NO GO Fixtures
Generate WI's for shipping and Packaging
* Define Lead time for consumables List
Second Aluminum Welder Training
Check Equipment (Chop Saw and Spool gun)
Confirm EAD for Brackets
Define Daily Output for the following 4 weeks
* Perform the Training Plan
Confirm tooling fixture Approval by Customer
Check with costumer if they need special documentation every shipment
Define Inspection Criteria (QS or Exemplis QA Inspection document)
Generate Gage R&R
Elaborate QA Control Plan and Sampling plans
Check Drawings Requirements
Generate the Control Plan
* A meeting will be held with Customer Service to determine RM safety stock
Check Firm WO for Production runs
Exemplis PPAP's Training
Confirm Firm WO for the following 3 months (Forecast)
Establish the Kanban Cards for Raw Material (If Applicable)
Establish the Kanban Cards for WIP's
Eliminate WIP's from BOM's
Fabricate painting cars for the Aviera Project
 Responsible
Lizbeth Federico
Eduardo Becerra
Antonio Reyna
Antonio Reyna
Antonio Reyna
Jose Hernandez
Jose Hernandez
Jose Hernandez
Jose Hernandez
Jose Hernandez
Jose Hernandez
Jose Hernandez
Jorge Zambrano
Jose Hernandez / Nitida Luis
Jose Hernandez
Jose Hernandez
Oscar Sanchez
Nitida Luis
Nitida Luis/Jose Hernandez
Adrian Raffie
JH/JP
Jose Hernandez
Antonio Reyna
Nitida L / Jose Padilla
Jose Hernandez / Jose Padilla
Jorge Zambrano/AR
JZ/LB
Jorge Zambrano
Jorge Zambrano
Jorge Zambrano
Jorge Zambrano/JH
Jorge Zambrano
Lizbeth Federico
Iris Martinez
Antonio Reyna
Antonio Reyna
Lizbeth Federico
Oscar Sanchez
Nitida Luis
Oscar S/ Nitida L
 Comments Date Status
Provide RM Availability (Nov 25th), only brackets pending 25-Nov
Dec 4th , 2015 (Provide std time Jose Hernandez), define Std time for the operations 25-Nov
 I will confirm on 11/26, birng a shipping car (Dec 2nd, 2015), Cars received 26-Nov Done
 Will be ready on 11/26, Dec 3th, 2015, Dec 8th, 2015 26-Nov Done
 We still pending feedback from Exemplis Javier told us will have it on 11/30 30-Nov
Capacity Matrix by Operation, Lay-Out and Process Map 4-Dec Done
Lay out completed, pending approval - Process Map completed 4-Dec Done
December 8th, 2015 4-Dec Done
Review with Padilla (December 8th, 2015) 4-Dec Done
11-Dec
Provide list to Adrian (Nov 26th), Generate the consumables list (Dec 8th, 2015) 11-Dec Done
Add to QS 11-Dec
Tentative 11-Dec
WI's will start today (Dec 8th, 2015) 14-Dec
Pending PPAP training, PFMEA will be completed Dec 15th, 2015) 21-Dec
Check with Oscar current saw availabilty 23-Dec
Define saw machine (new or used) 5-Jan
A meeting will be held for PFMEA and IQS 18-Dec
NEEDSHIPING CART HERE AT BIM 22-Dec
TBD
Obed (Second Shift Welder), start training TIG Dec 4th, 2015 11-Jan
Verify if the equipment is ready to operate 3-Dec Done
 You will have it today. TBD
A meeting will be held on Dec 3th, 2015 18-Dec
Padilla will check with Jose Traingin Special requirement, Dec 10th, 2015 7-Dec 12-Dec
Pending to discuss with Exemplis (Dec 2nd, 2015) TBD
Not special documentation requirement 1-Dec Done
A meeting will be held with Exemplis QA team ( Dec 3th) TBD
Define if Gage R&R is need it TBD
Pending ECD (Dec 11, th per customer request) 5-Jan
Pending ECD, (Discuss with customer CPK requirements) 2-Dec done
Pending ECD TBD
A meeting will be held with AR, IR, To define Type with Customer Agreedment 10-Dec
Iris will confirm firm Orders for January and February 12-Dec
schedule new date (Dec 2nd, 2015), Dec 11th, 2015 11-Dec
 We have a PO for 800 pcs and we need to make the Ramp Up plan.
A meeting will be held Dec 17th, 2015
9-Dec
15-Dec
Define numbers of cars, We already have the meeting 9-Dec
Another set of 100 units for running
(Start samples today Dec 8)

Pending ECD Dec 18th, 2015

Std times Dec 12, 2015

50%
PFMEA revisar con Nitida
30%
Solicitar materiales para booth soldadura

Falta diseñar para los procesos criticos

Hoy queda terminada
Francisco Alonso as a Back up

Mandar matrix de entrenamiento a Antonio Valle

Antonio Reyna revisar con personal de Exemplis para definición de cirterios

Listos para este viernes 18

Revisar tipo de inspecciones a realizar

Oscar revisara con Lizbeth niveles de inventario

Ya hay ordenes firmes

Oscar lo revisara con ella

Por definir
 NPI CHECKLIST REVIEW
Project Name Aviera Metal Arm Date Nov 19th, 2015
Project Number 1454 Customer Exemplis

Start Due Finish

Action/Question Apply Person Responsible Comment / Action Required Status
Date Date date
Phase I Design Review - - - - - - -
Sample, Specification and Drawings were provided by the Customer? Antonio Reyna Done

Is there new Part number assigned in SAP? Done

Is there new Part numbers RAW (tooling) assigned in SAP? Done
Is there new Part numbers RAW (purchase) assigned in SAP? Done
Is there new Part numbers WIP assigned in SAP? Done
The Minimum Order Quantity already negotiated with Customer Antonio Reyna 38 each per Car Done
Is Manufacturing Capacity Available? Jose Hernandez Check Aluminiun Welders Trained Personnel
Are New materials required? / Antonio Reyna Brackets (ETA Nov 26, 2015) Done
* Define Lead times to buy new materials Antonio Reyna Done
* Provide List of Consumables List Materials Requested Jose Hernandez Define List of Consumables & Kanban Implementation
Spool Gun (ETA Nov 20th, 2015), Chop Saw (Adrian Raffie
Machinery Review and Equipment Verification/Availability Jose Hernandez Pending ETA
Are Tooling and Fixturing Required? Jose Hernandez Modify Welding Bracket Fixture
* Define Lead times to build new fixtures Jose Hernandez Cutting Fixture (Pending to Fabricate)
* Tooling Customer Approval Jorge Zambrano /Lorena Berumen Double Check (Customer Fixturing List Approval)
Have Special Characteristics or Process Required? Done
* Is a Third Party required? Antonio Reyna Outsourcing Painting Process (EnAcero) Done
* Define Lead times with the External Process Antonio Reyna Done
Are Special Customer documentation request? Clarify with Customer
* Define List of Customer Documentation requested Jorge Zambrano/Lorena Berumen
Are testing already provided by the Customer?
* Confirm if you have all gages or eqipment to perform ISIR Jorge Zambrano Done
Are ready the Flow Chart? Jose Hernandez Develop a Flow Chart to identify Process Oportunities
Are ready to run the first samples or prototype? Jose Hernandez Approved by Customer Done

Approvals Signatures Date

Plant Manager
Project Leader
QA Supervisor
Engineering Supervisor
Materials Supervisors
 NPI CHECKLIST REVIEW
Project Name Aviera Metal Arm Date Nov 19th, 2015
Project Number 1454 CustoExemplis

Star Fini
Due
t sh
Action/Question Apply Person Responsible Dat Comment / Action Required Status
Dat Dat
e
e e
Phase II Prototype Review - - - - - - -
Are all specified tests, methods, equipment and acceptance criteria clearly defined and reflected in BIM Jorge Zambrano Development Inspection Criteria
procedures?
* Gage R& R already approved? Jorge Zambrano Develop the G R&R
Are sampling plans and in process audits ready to start prototype? Jorge Zambrano Check the Control Plan
Are there any requirements specified that cannot be evaluated using known inspection techniques? Jorge Zambrano Done
* Test gages already calibrated? Lorena Berumen Done
Is the incoming inspection procedure in place? Jorge Zambrano Done
Are tolerances compatible with accepted manufacturing standards? Jose Hernandez/Jorge Zambrano Confirm Detail D from 90-003786, check drawing
requirements
Is the BIM PPAP process completed? Antonio Reyna Confirm Customer PPAP's Approval
Are fixtures ready to start up prototype samples? Jose Hernandez Pending Cutting Fixture and Bracket Welding
Are the Drawing for incoming inspection ready?
Are the raw material ready for incoming inspection? Antonio Reyna Done
Is the BOM ready in SAP ? Nitida Luis Done
Are the visual aids or work instructions ready to start up with Prototype? Nitida Luis/Jose Hernandez Elaborate 6 WI's
Is the Production Availability Capacity Confirmed? Jose Hernandez Assemblers per station
Is the Prototype Shipping instructions defined? Jorge Zambrano Done
Are the assemblers/Operators already Trained? Jose Hdez/Jose Padilla Define training for the second welder (Update Training
Matrix)
Are the Raw Material Lists already available? Lizbeth Federico Check current RM inventory Review
Are the Consumable Lists already available? Jose Hernandez Pending
* Are the Lead times already defined? Adrian Rafiee Check LT's
Is the prototype already has Customer Approval? Antonio Reyna Done
Are ready the final inspection report? Antonio Reyna Done

Approvals Signatures Date

Plant Manager
Project Leader
QA Supervisor
Engineering Supervisor
Materials Supervisors
 NPI CHECKLIST REVIEW
Project Name Aviera Metal Arm Date Nov 19th, 2015
Project Number 1454 Customer Exemplis

Action/Question Apply Person Responsible Start Date Due Date Finish Date Comment / Action Required Status
Phase III (Production Review) - - - - - -
Manufacturing Flow Chart and Lay-Out already finished? Jose Hernandez Implementation Plan
* Is the manufacturing Cell assigned? Cutting Process Station, Welding Booth
* Packaging specifications Customer Approval Nitida Luis Packaging and Shipping WI
* Ramp Up plan for Production Jose Padilla Defiine Learning Curve and 4 weeks estimated output

Is the raw material ready for incoming inpection Jorge Zambrano Done
QA inspectors already trained and certified? Jorge Zambrano Training for QA Inspectors
Assemblers/Operators already Certified? Jose Hdez/Jose Padilla Trainin Plan for Asemblers and Welders
Are the PFMEA and Control Plan completed? Jorge Zambrano/ Jose Hdez Elaborate GO/NO GO Fixtures, Elaborate PFMEA and
Control Plans
Is the BOM already completed in SAP? Nitida Luis Done
Is the 3 months forecast already provided by the Customer? Antonio Reyna Check future WO's for the following 3 months
Is the Customer Liason List already provided? Antonio Reyna Define Point of Contact for all Department
Are the Packaging and Shippings instructions already provided? Antonio Reyna Define WI's and customer agreedment documentation

* Include packaging in BOM Antonio Reyna Check with Nitida (Shrim Grap)
* Packaging specifications Customer Approval Antonio Reyna To Confirm
Will BIM required to provide certification in each shipment? Antonio Reyna
* Provide Training and Shipping Special Documents instructions If applicable
Is the PPAP completed and approved by the Customer? Jorge Zambrano Pending by Customer
Is the Kanban Cards already place on the whse? Lizbeth Federico Pending Kanban Cards Calculation, A meeting will be
held with CS to define Inventory Stock
Are the equipment, tooling, gages and fixturing already has PM's? Jose Hernandez Elaborate TPM and PM's
Place Production Customer WorkOrder Valentin Terrazas To Confirm

Approvals Signatures Date

Plant Manager
Project Leader
QA Supervisor
Engineering Supervisor
Materials Supervisors
 NPI CHECKLIST REVIEW
Project Name Aviera Metal Arm Date Nov 19th, 2015
Project Number 1454 Customer Exemplis

Action/Question Apply Person Responsible Start Date Due Date Finish Date Comment / Action Required Status
Phase IV ( Project Closure) - - - - - - -
Process Flow Diagram, Lay-Out and Inspection Plan completed Engineering/Quality Supervisors
PFMEA and Control plan in place? Engineering/Quality Supervisors
Sampling and inspection plans in Place? Quality Supervisors
*Incoming and FG Including testing Quality Supervisors
Packaging and Shipping Specifications Engineering Supervisor
* First WorkOrder Completed and ready for shipment Manufacturing Supervisor
BOM already in SAP Engineering Supervisor
Preventive Maintenance Plans Equipment Engineer
Process Monitoring and Operations Instructions Manufacturing Supervisor
Training Certificates Quality Supervisors
Customer PPAP Approval Quality Supervisors
QA Final Release Quality Supervisors
Lesson Learned Project Leader
Project Closure Minute Project Leader
Party Time

Approvals Signatures Date

Plant Manager
Project Leader
QA Supervisor
Engineering Supervisor
Materials Supervisors
 Contact List
Exemplis Phone
Quality Gerardo Castro
Sourcing Specialist Yvette Alarcon 714.995.4800 x 461
Product Engineer Adam Huennekens (714)995-4800 ext. 441
Sourcing – Mexico Javier Huerta 664 331 64 31
t
Email
GCastro@exemplis.com
YAlarcon@exemplis.com
AHuennekens@exemplis.com
JHuerta@exemplis.com
 Process MAP 90-003786-01
3 Stringer RH Bottom Metal Front Bottom
Cap Rear Leg arm Top Plate
Cutting 3 6 2 Bending 4 1 Leg Cap
Purchased Bending Cutting 5 Purchased
Purchased Cutting 6 Purchased

3A Stringer RH 3A Rear leg

Fron Leg
Punching 2A
Cutting
7A
Welding SUB-ASSY 1

7B Welding SUB-ASSY 2 7C Welding SUB-ASSY 3

7 Falta agregar proceso de pintura externo

Welding Assy Final

8 External
Painting
Polishing

9
Packaging
Painting

10
Packaging
10
Packaging
 90-003786-01
Process Std Time Set-up Process Step

Front leg, AVIERA cutting 90 seg 1

10 min

Rear Leg Bending 55 seg 2

5 min

Rear leg Cutting 95 seg 2A

10 min

Stringer RH Cutting 90 seg 3

15 min

Stringer RH Knotch Punching 40 seg 3A

60 min

Metal Arm TubeCutting 60 seg 4

10 min

Top Pate Pending Pending 5

Bottom Cap Curved Arm Pending Pending 6

Welding Assy 1 Pending Pending 7A

Welding Assy 2 Pending Pending 7B

Welding Assy 3 Pending Pending 7C

AVIERA Metal Arm RH Welding Final Assy Pending Pending 7

External Polishing Pending Pending 8

Painting (Enacero) Pending Pending 9

Packaging Pending Pending 10

Packaging Pending Pending 10
 Part number Comments Personal
WI-Ready
90-002304 Remove sharp edges
Salvador/Jaime
WI-Ready
Salvador/
90-002303 Remove sharp edges Armando
Cutting fixture pending Minguer
WI's pending,
90-002303 TrainingPending
Salvador/Jaime
WI-Ready
90-002950
Salvador/Jaime
WI's pending,
90-002950 Validate Die
Salvador/Jaime

90-004385 WI-Ready
Salvador/Jaime
Purchased
Juan
90-004384 Castillo/Marco
Aldama
Purchased
Juan
90-002342 Castillo/Marco
Aldama
WI's pending,
Assy 90-003084 and 90-
003085 Weld Set up Sheet Pending
Francisco Alonso
WI's pending,
Assy 1 plus 90-002303
and 90-002342. Weld Set up Sheet Pending
Francisco Alonso
WI's pending,
Assy 1 plus 90-002304
and 90-002342. Weld Set up Sheet Pending
Francisco Alonso
Assy 1+ Assy2 + Assy 3 WI's pending,
and 90-002950 (Final Weld Set up Sheet Pending
Assy) Francisco Alonso
WI's pending,
90-003786
Francisco Alonso
WI's pending,
90-003786-01
Francisco Alonso
WI's pending,
90-003786-01
Francisco Alonso
90-003786-01
Francisco Alonso
 Process MAP 90-003786-01
Stringer LH Bottom Metal Front Bottom
3 Cap Rear Leg Top Plate
Cutting 3 6 2 arm 1 Leg Cap
Purchased Bending
Bending 4 Cutting 5 Purchased
Purchased Cutting 6 Purchased

3A Stringer LH 3A 2A Rear leg

Fron Leg
Punching Cutting
7A
Welding SUB-ASSY 1

7B Welding SUB-ASSY 2 7C Welding SUB-ASSY 3

7 Welding Assy Final

8 External
Painting
Polishing

9
Packaging
Painting

10
Packaging
10
Packaging
L29A3:L34 0) 15 piezas por numero de parte
a) Negociar dado y corte en corte Eduardo

1) Validar el proceso de doblado Jose

a) Cortar las 20 piezas
b) Pasarlas a Calidad para que las mida y las validen Nitida

2) Pasar las piezas a Calidad

a) 5 piezas por número de parte Nitida
b) Validar piezas del dado

3) Revisar con Francisco correcta colocación de los brackets antes de soldar Jose

4) Fixtura del Ensamble 1

a) Revisión visual de las partes ya soldadas Jose/Nitida

5) Revisar el gap del stringler

a) Modificar las tolarencias para corte y doblado Jose/Nitida

6) Revisar fixtura para soldar ensamble 2 y 3

a) ISIR de las piezas para evitar partes fuera de especificación Jose/Nitida

7) Agregar a la WI que se limpie los manchas negras

a) Revisar si se elimina con Francisco Saul/Nitida
b) O durante el proceso de Pulido

8) Criterios de aceptacion en soldadura

a) Revisar con Calidad, hacer junta con todo el grupo Jorge/Eduardo

9) Revisar que Francisco se asigne 100% a Aviera y Hip Chair Eduardo

a) Incluyendo overtime

10) Disponibilidad para pintar las piezas, Eduardo,

a) Martes por la mañana

10) Revisar voltaje para colacion de booth nuevo de soldadura

a) Solicitar materiales

11) Lista de consumibles

a) Meterlo a Kanban
Jose/Nitida

Jose/Nitida

Jose/Nitida

Saul/Nitida

Jorge/Eduardo
 90-003786-01
Process Std Time Set-up Process Step

Front leg, AVIERA cutting 90 seg 1

10 min

Rear Leg Bending 55 seg 2

5 min

Rear leg Cutting 95 seg 2A

10 min

Stringer LH Cutting 90 seg 3

15 min

Stringer LH Knotch Punching 40 seg 3A

60 min

Metal Arm TubeCutting 60 seg 4

10 min

Top Pate N/A N/A 5

Bottom Cap Curved Arm Pending Pending 6

Welding Assy 1 Pending Pending 7A

Welding Assy 2 Pending Pending 7B

Welding Assy 3 Pending Pending 7C

AVIERA Metal Arm RH Welding Final Assy Pending Pending 7

External Polishing Pending Pending 8

Painting (Enacero) Pending Pending 9

Packaging Pending Pending 10

Packaging Pending Pending 10
 Part number Comments Personal
WI-Ready
90-002304 Remove sharp edges
Salvador/Jaime
WI-Ready
Salvador/
90-002303 Remove sharp edges Armando
Cutting fixture pending Minguer
WI's pending,
90-002303 TrainingPending
Salvador/Jaime
WI-Ready
90-003788
Salvador/Jaime
WI's pending,
90-003788 Validate Die
Salvador/Jaime

90-004385 WI-Ready
Salvador/Jaime
Purchased
Juan
90-004384 Castillo/Marco
Aldama
Purchased
Juan
90-002342 Castillo/Marco
Aldama
WI's pending,
Assy 90-003084 and 90-
003085 Weld Set up Sheet Pending
Francisco Alonso
WI's pending,
Assy 1 plus 90-002303
and 90-002342. Weld Set up Sheet Pending
Francisco Alonso
WI's pending,
Assy 1 plus 90-002304
and 90-002342. Weld Set up Sheet Pending
Francisco Alonso
Assy 1+ Assy2 + Assy 3 WI's pending,
and 90-002950 (Final Weld Set up Sheet Pending
Assy) Francisco Alonso
WI's pending,
90-003786
Francisco Alonso
WI's pending,
90-003786-01
Francisco Alonso
WI's pending,
90-003786-01
Francisco Alonso
90-003786-01
Francisco Alonso
 Process MAP 90-003786-01
Stringer LH Bottom Metal Front
3 Rear Leg arm Top Plate Bottom
Cutting 3 6 Cap Laser 2 Bending 4 1 Leg
Purchased Bending Cutting 5 Laser
Purchased Cutting 6 Cap Laser
Purchased

Stringer LH 3A Bottom Cap Rear leg

Fron Leg
3A Punching 6A 2A
Machinary Cutting
7A
Welding SUB-ASSY 1

7B Welding SUB-ASSY 2 7C Welding SUB-ASSY 3

7 Welding Assy Final

8 External
Painting
Polishing

9
Packaging
Painting

10
Packaging
10
Packaging
 Consumables List
Welding Gloves
Contact tips 528172-1
Weld wire Pending define
Argon (GAS) Pending define
Cutting Blades
Deburring Blades
Grease
Tweezers
Apron (Mandil)
Sleves (Mangas)
Maquina lincon
Carrete de alambre de al4043 de .035
Boquilla GAS KP3075-1-50F
Antorcha magnum pro 5 s
730 pcs per Month (Max) 36 per day
600 pcs per Month (Target)
450 pcs per Month (Min)
Close to 38 per day
We need the time for process
Eliminate WIPS
Jose-Evaluara proceso para hoy la lista de cortadires automaticos
Jose-Evaluara cortadora automatica (lista)
Weld Mixx aluminum
t403500xx
Lunes
NP Procceso
90-002950/003788-90 Dado Probado validado por Ingeneria/CMM
 Puntos a revisar en un plano
1 circulos con 3 acotaciones

2 Coincidir toleancias de proveedor del material con

tolerancias de los planos internos
3 tipo de material
4 tipo de acabado
5 tipo de pintura
6 Necesidad de simbolo de Planicidad
7 Necesidad de simbolo de Concentricidad
8 Necesidad de simbolo de Paralelismo