Internal #

Guidelines to use Process DFM t

# Guidelines
1 Process DFM is a living document. The DFM document should be updated to reflect approved Tesla SIE changes in the ma
design. It shall be submitted and approved by SIE during the RFQ/ before sourcing.

2 Process DFM consists of: (a) Process Flow (b) BOM Summary (c) Manufacturing Line Layout (d) Operation Template 1 (e)

3 Process Flow: Supplier must fill out all the processes and activities from incoming inspection and material release for pro

4 BOM Summary: All sub-components, raw materials must be covered in the BOM summary.

5 Manufacturing line layout:

- Attach Tesla manufacturing line layout and identify and label each work station according to the process flow in the layo
- CAD layout should be legible with clear identification of storage areas, material flow and packaging areas

6 Guidelines for Operation template 1 (refer DFM example worksheet for clarification):
- Detailed description of operation must be supplemented with actual process and equipment images
- Naming Convention for the operation template should be Operation # _ 1 for Operation template 1 of 2, Operation # _2
as Operation #10 _ 1, and Operation #10 _ 2.

7 Guidelines for Operation template 2 (refer DFM example Red-rabbit master worksheet for clarification):
- Provide detailed description on inspection methodology and inspection system along with tolerance/specification. Supp
frequency on the product along with equipment calibration frequency must be specified for each inspection system.
- Follow naming convention as mentioned above.

8 Product traceability must follow requirements of BMS-0000151 (refer Supplier Portal for latest revision)
 Internal #

use Process DFM template Tesla DOC-0015819 rev 1

Guidelines
ct approved Tesla SIE changes in the manufacturing process/equipment/process or product specification and/or product
.

ne Layout (d) Operation Template 1 (e) Operation Template 2

inspection and material release for production to final packaging and labeling.

ummary.

according to the process flow in the layout.

flow and packaging areas

on):
d equipment images
peration template 1 of 2, Operation # _2 for Operation Template 2 of 2. For example: If the operation #10 will be named

sheet for clarification):

along with tolerance/specification. Supplement the inspection point with appropriate image/HMI output. Inspection
ecified for each inspection system.

rtal for latest revision)

 DOC-0015819 Internal #

Tesla DOC-0015819 rev 1

Process Flowchart
Product Program OPAL PAB Issue Date
Supplier Name ZF Occupant Safety Systems de la Laguna Part Name TBD
Supplier Location Gómez Palacio, Dgo. Part Number TBD

Legend:

Operation Material Movement / Transportation Inspection Delay Storage

Step #: 1
Name: Incoming Inspection (As applicable per model)
Equipment Used: Warehouse
Process Owner: Incoming Department

Step #: 2
Name: Material Storage
Equipment Used: Warehouse Racks
Process Owner: Warehouse Coordinator

Step #: 3
Name: Issuing the components to production area according to FIFO
Equipment Used: Forklift / hydraulic skate
Process Owner: Material Manager

Step #: 4
Name: Delivery of the components at production line
Equipment Used: Racks, WIPS.
Process Owner: Production Supervisor

Step #: 100
Name: Retainer insertion
Equipment Used: Assited Machine
Process Owner: Manufacturing Engineer

Step #: 110
Name: TAU assembly
Equipment Used: Assited Machine
Process Owner: Manufacturing Engineer

Step #: 120
Name: Automatic Folding Station + Bag Wrap closing
Equipment Used: Automatic folding station
Process Owner: Manufacturing Engineer

Step #: 130
Name: Automatic TAU retainer assembly + Screwing station
Equipment Used: Station tightening screwdriver controller
Process Owner: Manufacturing Engineer

Step #: 140
Name: Control station + Labeling + Final inspection
Equipment Used: Station Printer + PC + Scanner + Traceabilty
Process Owner: Manufacturing Engineer

Step #: 150
Name: DLN
Equipment Used: Work table
Process Owner: Quality Engineer

Step #: 160
Name: Material Storage
Equipment Used: Warehouse Racks
Process Owner: Warehouse Coordinator

Step #: 170
Name: Finished Goods Shipped
Equipment Used: NA
Process Owner: Shipping Manager
 Internal #

Include all child parts and sourcing information

# Tier-Level Part Number Part Descripton Photo of product

1 TBD CV A027C482 A DI 10.2 G67 TBD

3D Square Shape ABV +

2 TBD CV R000H715 A SAVe PA 700 dtex Silicon TBD
Coated 140 Liter

3 TBD CV R000H714 A Stamped Welded TBD

4 TBD A020L696 A DI10 Type 1,0 mm TBD

5 TBD 30372507 C M6 TBD

6 TBD 34229854 C Orientation 0° HAS TBD

Plastic Molding PA6-GF40

7 TBD 34289370 A TBD
Akulon K224-PG8
 Internal #

LRD Flap - 585 DTEX Coated PN

8 TBD A023M185 A TBD
11040843

9 TBD A015E431 D Fabric Cover TBD

10 TBD 34087872 B PET-Type TBD

 Internal #

Bill of Materials Summary

Process/ Assembly Station

Raw Material Name Quantity per assembly # (Create hyperlink to the Supplier Name
procee tab)

Inflator 1 TBD

Bag 1 TBD

Housing 1 TBD

Retainer Bag 1 TBD

NUT 4 TBD

TAU 1 TBD

TAU Retainer 1 TBD

 Internal #

COVER 1 TBD

COVER 1 TBD

Label Documentation 1 TBD

 Internal #

mmary

Inspection Standard to be
Subcomponents-DFM completed for each Subcomponent PPAP
Supplier Location
Attachment incoming raw material status (attach PSW).
following Tesla's template

TBD TBD TBD

Inspection
Standard.xlsm

TBD TBD TBD

TBD TBD TBD

TBD TBD TBD

TBD TBD TBD

TBD TBD TBD

TBD TBD TBD

 Internal #

TBD TBD TBD

TBD TBD TBD

TBD TBD TBD

 Internal #

Tesla DOC-0015819 rev 1

Traceability Grade# (Serial Number, Batch)

(per Tesla BMS-0000151 Tracebility
Specification)

C
 Internal #

C
 Internal #

Process/Equipment Layo

Please prepare a proposed CAD layout for the manufacturing proce

Preliminary
please include material storage areas, label

Operation
Process Name / Description
Number
100 Bag retainer assembly into bag

110 TAU assembly

120 Automatic Folding Station + Bag Wrap closing

130 TAU retainer assembly + Screwing station

140 Control station + Labeling + Final inspection

Internal #
 Internal #

Equipment Layout Details Tesla DOC-0015819 rev 1

for the manufacturing process (line layout), overall factory layout –

Preliminary
e material storage areas, label process steps

Process Owner HyperLink (Operation Template)

Manufacturing Engineer

Manufacturing Engineer

g Manufacturing Engineer

Manufacturing Engineer

Manufacturing Engineer
Internal #
 Internal #

Operation Template 1:
(Required for each process step, plea

Process Station Number 100

Image

Image of Process (including tool, equipment, machine)

(May use CAD model if not hard tooled yet)

Detailed description of operation steps

Process (100% Robotic, Semi-robotic, Manual)

Number of Operators required

Machine / Equipment Name and Model

Tooling
 Internal #

Equipment Parameters

Equipment/Tooling/Raw material Lead time

Cycle time per unit/per station

Expected OEE

Spec/Acceptance Criteria (Please enter the specification with the tolerances)

Error proofing detections for each step and frequency of inspection

BOM Material (Added / Removed)

Tracebility Grade#

Tracebility Data stored against sn#

Preventive Maintenance (PM) and Calibration of Equipment

(Please attach schedule daily/weekly/monthly/yearly and requirements)

Spare parts list for Equipment, Tooling

 Internal #

ation Template 1: Process DFM

(Required for each process step, please replicate the operation template page 1 and page 2 for each step of the mfg process)

Process Name Bag retainer assembly into bag

Image of product
(May use actual image or CAD model but must represent process inputs, value addition and output)

Provide detailed processes and operations step by step.

Following definitions should be used to identify the nature of process:

1. 100% Automatic process: Automatic processing of the product. Automatic material handling into and out of the station.
Automatic inspection of the product with automatic rejection of NG products.
2. Semi Automatic process: Automatic processing of the product with manual loading and unloading of the produt into the station.
Automatic inspection of the product with automatic rejection of NG products.
3. Manual process: Manual processing of the product with manual loading and unloading of the production into the station. Manual
inspection of the product. (e.g. wire harness installation/protective cap installation etc.)

Provide detailes on number of operator required for this operation and their work instructions.

Provide details of all machines/equipment name, model, mfg year used in this operation.

Provide details on the tooling required in this operation, along with tooling details: number of cavities, material, type of
operation, # of tooling per equipment/operation and projected tool life.
 Internal #

Enter all equipment, and it's parameters. For e.g. Torque gun RPM, CNC Spindle RPM, Brazing oven temperature,
Force/Displacement parameters, vision system: field of view, resolution, accuracy.

1) Template attached (Follow the example in the template)

2) After the template is filled, save and attach the filled template in the next
row

Provide cycle time details for this operation. Cycle time per station (please clearly specify number of duplicate stations):
1. For single flow material/production: Provide detailed breakdown of loading time, unloading time, inspection time and
processing time for one unit
2. For batch production (E.g. Brazing, heat treatment, cleaning etc): Provide detailed breakdown of loading time,
unloading time, inspection time and processing time for one batch along with the batch size.

1) Use the template attached for the capacity. Fill out the 'Process Capacity
Study' Tab in the template for designed capacity (as per guidelines in the
template).
2) After the template is filled, save and attach the filled template in the next
row

Product feature/ Process parameter Spec/Tolerance

Complete Operation Template 2 of 2 (Hyperlinked)

Provide details on BOM material added/removed in this operation. BOM material must be mentioned in the BOM summary

Tracebility Grade as per design/SIE requirement, attach image for the barcode

Enter all process, tracebility including red-rabbit, master-sample verfication data. For. E.g. Torque/Angle,
displacement/force, temperature, dimensionals, images stored (example of the image)

Attach detailed Preventive Maintenance (PM).

-Daily/weekly/monthly/yearly preventive maintenance schedule and checklist for each machine/tool

Please provide list of all spare parts for the tooling and equipment used in this operation. Spares need to kept to ensure
continous production to meet Tesla EDI. For example: Extra set of tooling, backup cameras, fixtures, robot, sensors,
actuators, etc.
 Internal #

Tesla DOC-0015819 rev 1

for each step of the mfg process)

ner assembly into bag

duct
nt process inputs, value addition and output)

perations step by step.

dentify the nature of process:

t. Automatic material handling into and out of the station.
tomatic rejection of NG products.
h manual loading and unloading of the produt into the station.
tomatic rejection of NG products.
ading and unloading of the production into the station. Manual
allation/protective cap installation etc.)

this operation and their work instructions.

model, mfg year used in this operation.

ith tooling details: number of cavities, material, type of

peration and projected tool life.
 Internal #

RPM, CNC Spindle RPM, Brazing oven temperature,

m: field of view, resolution, accuracy.

Template

Subcomponent_Too
l_Equipmen
t_Tracker. xlsx

on (please clearly specify number of duplicate stations):

own of loading time, unloading time, inspection time and
r one unit
ing etc): Provide detailed breakdown of loading time,
e for one batch along with the batch size.

Template

Validation of
Capacity OEE.xlsm

Spec/Tolerance

2 of 2 (Hyperlinked)

BOM material must be mentioned in the BOM summary

ment, attach image for the barcode

sample verfication data. For. E.g. Torque/Angle,

images stored (example of the image)

Maintenance (PM).
schedule and checklist for each machine/tool

nt used in this operation. Spares need to kept to ensure

t of tooling, backup cameras, fixtures, robot, sensors,
tc.
 Internal #

Operation Template 1:
(Required for each process step, plea

Process Station Number 110

Image

Image of Process (including tool, equipment, machine)

(May use CAD model if not hard tooled yet)

Detailed description of operation steps

Process (100% Robotic, Semi-robotic, Manual)

Number of Operators required

Machine / Equipment Name and Model

Tooling
 Internal #

Equipment Parameters

Equipment/Tooling/Raw material Lead time

Cycle time per unit/per station

Expected OEE

Spec/Acceptance Criteria (Please enter the specification with the tolerances)

Error proofing detections for each step and frequency of inspection

BOM Material (Added / Removed)

Tracebility Grade#

Tracebility Data stored against sn#

Preventive Maintenance (PM) and Calibration of Equipment

(Please attach schedule daily/weekly/monthly/yearly and requirements)

Spare parts list for Equipment, Tooling

 Internal #

ation Template 1: Process DFM

(Required for each process step, please replicate the operation template page 1 and page 2 for each step of the mfg process)

Process Name TAU assembly

Image of product
(May use actual image or CAD model but must represent process inputs, value addition and output)

Provide detailed processes and operations step by step.

Following definitions should be used to identify the nature of process:

1. 100% Automatic process: Automatic processing of the product. Automatic material handling into and out of the station.
Automatic inspection of the product with automatic rejection of NG products.
2. Semi Automatic process: Automatic processing of the product with manual loading and unloading of the produt into the station.
Automatic inspection of the product with automatic rejection of NG products.
3. Manual process: Manual processing of the product with manual loading and unloading of the production into the station. Manual
inspection of the product. (e.g. wire harness installation/protective cap installation etc.)

Provide detailes on number of operator required for this operation and their work instructions.

Provide details of all machines/equipment name, model, mfg year used in this operation.

Provide details on the tooling required in this operation, along with tooling details: number of cavities, material, type of
operation, # of tooling per equipment/operation and projected tool life.
 Internal #

Enter all equipment, and it's parameters. For e.g. Torque gun RPM, CNC Spindle RPM, Brazing oven temperature,
Force/Displacement parameters, vision system: field of view, resolution, accuracy.

1) Template attached (Follow the example in the template)

2) After the template is filled, save and attach the filled template in the next
row

Provide cycle time details for this operation. Cycle time per station (please clearly specify number of duplicate stations):
1. For single flow material/production: Provide detailed breakdown of loading time, unloading time, inspection time and
processing time for one unit
2. For batch production (E.g. Brazing, heat treatment, cleaning etc): Provide detailed breakdown of loading time,
unloading time, inspection time and processing time for one batch along with the batch size.

1) Use the template attached for the capacity. Fill out the 'Process Capacity
Study' Tab in the template for designed capacity (as per guidelines in the
template).
2) After the template is filled, save and attach the filled template in the next
row

Product feature/ Process parameter Spec/Tolerance

Complete Operation Template 2 of 2 (Hyperlinked)

Provide details on BOM material added/removed in this operation. BOM material must be mentioned in the BOM summary

Tracebility Grade as per design/SIE requirement, attach image for the barcode

Enter all process, tracebility including red-rabbit, master-sample verfication data. For. E.g. Torque/Angle,
displacement/force, temperature, dimensionals, images stored (example of the image)

Attach detailed Preventive Maintenance (PM).

-Daily/weekly/monthly/yearly preventive maintenance schedule and checklist for each machine/tool

Please provide list of all spare parts for the tooling and equipment used in this operation. Spares need to kept to ensure
continous production to meet Tesla EDI. For example: Extra set of tooling, backup cameras, fixtures, robot, sensors,
actuators, etc.
 Internal #

Tesla DOC-0015819 rev 1

for each step of the mfg process)

TAU assembly

duct
nt process inputs, value addition and output)

perations step by step.

dentify the nature of process:

t. Automatic material handling into and out of the station.
tomatic rejection of NG products.
h manual loading and unloading of the produt into the station.
tomatic rejection of NG products.
ading and unloading of the production into the station. Manual
allation/protective cap installation etc.)

this operation and their work instructions.

model, mfg year used in this operation.

ith tooling details: number of cavities, material, type of

peration and projected tool life.
 Internal #

RPM, CNC Spindle RPM, Brazing oven temperature,

m: field of view, resolution, accuracy.

Template

Subcomponent_Too
l_Equipmen
t_Tracker. xlsx

on (please clearly specify number of duplicate stations):

own of loading time, unloading time, inspection time and
r one unit
ing etc): Provide detailed breakdown of loading time,
e for one batch along with the batch size.

Template

Validation of
Capacity OEE.xlsm

Spec/Tolerance

2 of 2 (Hyperlinked)

BOM material must be mentioned in the BOM summary

ment, attach image for the barcode

sample verfication data. For. E.g. Torque/Angle,

images stored (example of the image)

Maintenance (PM).
schedule and checklist for each machine/tool

nt used in this operation. Spares need to kept to ensure

t of tooling, backup cameras, fixtures, robot, sensors,
tc.
 Internal #

Operation Template 1:
(Required for each process step, plea

Process Station Number 120

Image

Image of Process (including tool, equipment, machine)

(May use CAD model if not hard tooled yet)

Detailed description of operation steps

Process (100% Robotic, Semi-robotic, Manual)

Number of Operators required

Machine / Equipment Name and Model

Tooling
 Internal #

Equipment Parameters

Equipment/Tooling/Raw material Lead time

Cycle time per unit/per station

Expected OEE

Spec/Acceptance Criteria (Please enter the specification with the tolerances)

Error proofing detections for each step and frequency of inspection

BOM Material (Added / Removed)

Tracebility Grade#

Tracebility Data stored against sn#

Preventive Maintenance (PM) and Calibration of Equipment

(Please attach schedule daily/weekly/monthly/yearly and requirements)

Spare parts list for Equipment, Tooling

 Internal #

ation Template 1: Process DFM

(Required for each process step, please replicate the operation template page 1 and page 2 for each step of the mfg process)

Process Name Automatic Folding Station + Bag Wrap closing

Image of product
(May use actual image or CAD model but must represent process inputs, value addition and output)

Provide detailed processes and operations step by step.

Following definitions should be used to identify the nature of process:

1. 100% Automatic process: Automatic processing of the product. Automatic material handling into and out of the station.
Automatic inspection of the product with automatic rejection of NG products.
2. Semi Automatic process: Automatic processing of the product with manual loading and unloading of the produt into the station.
Automatic inspection of the product with automatic rejection of NG products.
3. Manual process: Manual processing of the product with manual loading and unloading of the production into the station. Manual
inspection of the product. (e.g. wire harness installation/protective cap installation etc.)

Provide detailes on number of operator required for this operation and their work instructions.

Provide details of all machines/equipment name, model, mfg year used in this operation.

Provide details on the tooling required in this operation, along with tooling details: number of cavities, material, type of
operation, # of tooling per equipment/operation and projected tool life.
 Internal #

Enter all equipment, and it's parameters. For e.g. Torque gun RPM, CNC Spindle RPM, Brazing oven temperature,
Force/Displacement parameters, vision system: field of view, resolution, accuracy.

1) Template attached (Follow the example in the template)

2) After the template is filled, save and attach the filled template in the next
row

Provide cycle time details for this operation. Cycle time per station (please clearly specify number of duplicate stations):
1. For single flow material/production: Provide detailed breakdown of loading time, unloading time, inspection time and
processing time for one unit
2. For batch production (E.g. Brazing, heat treatment, cleaning etc): Provide detailed breakdown of loading time,
unloading time, inspection time and processing time for one batch along with the batch size.

1) Use the template attached for the capacity. Fill out the 'Process Capacity
Study' Tab in the template for designed capacity (as per guidelines in the
template).
2) After the template is filled, save and attach the filled template in the next
row

Product feature/ Process parameter Spec/Tolerance

Complete Operation Template 2 of 2 (Hyperlinked)

Provide details on BOM material added/removed in this operation. BOM material must be mentioned in the BOM summary

Tracebility Grade as per design/SIE requirement, attach image for the barcode

Enter all process, tracebility including red-rabbit, master-sample verfication data. For. E.g. Torque/Angle,
displacement/force, temperature, dimensionals, images stored (example of the image)

Attach detailed Preventive Maintenance (PM).

-Daily/weekly/monthly/yearly preventive maintenance schedule and checklist for each machine/tool

Please provide list of all spare parts for the tooling and equipment used in this operation. Spares need to kept to ensure
continous production to meet Tesla EDI. For example: Extra set of tooling, backup cameras, fixtures, robot, sensors,
actuators, etc.
 Internal #

Tesla DOC-0015819 rev 1

for each step of the mfg process)

ng Station + Bag Wrap closing

duct
nt process inputs, value addition and output)

perations step by step.

dentify the nature of process:

t. Automatic material handling into and out of the station.
tomatic rejection of NG products.
h manual loading and unloading of the produt into the station.
tomatic rejection of NG products.
ading and unloading of the production into the station. Manual
allation/protective cap installation etc.)

this operation and their work instructions.

model, mfg year used in this operation.

ith tooling details: number of cavities, material, type of

peration and projected tool life.
 Internal #

RPM, CNC Spindle RPM, Brazing oven temperature,

m: field of view, resolution, accuracy.

Template

Subcomponent_Too
l_Equipmen
t_Tracker. xlsx

on (please clearly specify number of duplicate stations):

own of loading time, unloading time, inspection time and
r one unit
ing etc): Provide detailed breakdown of loading time,
e for one batch along with the batch size.

Template

Validation of
Capacity OEE.xlsm

Spec/Tolerance

2 of 2 (Hyperlinked)

BOM material must be mentioned in the BOM summary

ment, attach image for the barcode

sample verfication data. For. E.g. Torque/Angle,

images stored (example of the image)

Maintenance (PM).
schedule and checklist for each machine/tool

nt used in this operation. Spares need to kept to ensure

t of tooling, backup cameras, fixtures, robot, sensors,
tc.
 Internal #

Operation Template 1:
(Required for each process step, plea

Process Station Number 130

Image

Image of Process (including tool, equipment, machine)

(May use CAD model if not hard tooled yet)

Detailed description of operation steps

Process (100% Robotic, Semi-robotic, Manual)

Number of Operators required

Machine / Equipment Name and Model

Tooling
 Internal #

Equipment Parameters

Equipment/Tooling/Raw material Lead time

Cycle time per unit/per station

Expected OEE

Spec/Acceptance Criteria (Please enter the specification with the tolerances)

Error proofing detections for each step and frequency of inspection

BOM Material (Added / Removed)

Tracebility Grade#

Tracebility Data stored against sn#

Preventive Maintenance (PM) and Calibration of Equipment

(Please attach schedule daily/weekly/monthly/yearly and requirements)

Spare parts list for Equipment, Tooling

 Internal #

ation Template 1: Process DFM

(Required for each process step, please replicate the operation template page 1 and page 2 for each step of the mfg process)

Process Name TAU retainer assembly + Screwing station

Image of product
(May use actual image or CAD model but must represent process inputs, value addition and output)

Provide detailed processes and operations step by step.

Following definitions should be used to identify the nature of process:

1. 100% Automatic process: Automatic processing of the product. Automatic material handling into and out of the station.
Automatic inspection of the product with automatic rejection of NG products.
2. Semi Automatic process: Automatic processing of the product with manual loading and unloading of the produt into the station.
Automatic inspection of the product with automatic rejection of NG products.
3. Manual process: Manual processing of the product with manual loading and unloading of the production into the station. Manual
inspection of the product. (e.g. wire harness installation/protective cap installation etc.)

Provide detailes on number of operator required for this operation and their work instructions.

Provide details of all machines/equipment name, model, mfg year used in this operation.

Provide details on the tooling required in this operation, along with tooling details: number of cavities, material, type of
operation, # of tooling per equipment/operation and projected tool life.
 Internal #

Enter all equipment, and it's parameters. For e.g. Torque gun RPM, CNC Spindle RPM, Brazing oven temperature,
Force/Displacement parameters, vision system: field of view, resolution, accuracy.

1) Template attached (Follow the example in the template)

2) After the template is filled, save and attach the filled template in the next
row

Provide cycle time details for this operation. Cycle time per station (please clearly specify number of duplicate stations):
1. For single flow material/production: Provide detailed breakdown of loading time, unloading time, inspection time and
processing time for one unit
2. For batch production (E.g. Brazing, heat treatment, cleaning etc): Provide detailed breakdown of loading time,
unloading time, inspection time and processing time for one batch along with the batch size.

1) Use the template attached for the capacity. Fill out the 'Process Capacity
Study' Tab in the template for designed capacity (as per guidelines in the
template).
2) After the template is filled, save and attach the filled template in the next
row

Product feature/ Process parameter Spec/Tolerance

Complete Operation Template 2 of 2 (Hyperlinked)

Provide details on BOM material added/removed in this operation. BOM material must be mentioned in the BOM summary

Tracebility Grade as per design/SIE requirement, attach image for the barcode

Enter all process, tracebility including red-rabbit, master-sample verfication data. For. E.g. Torque/Angle,
displacement/force, temperature, dimensionals, images stored (example of the image)

Attach detailed Preventive Maintenance (PM).

-Daily/weekly/monthly/yearly preventive maintenance schedule and checklist for each machine/tool

Please provide list of all spare parts for the tooling and equipment used in this operation. Spares need to kept to ensure
continous production to meet Tesla EDI. For example: Extra set of tooling, backup cameras, fixtures, robot, sensors,
actuators, etc.
 Internal #

Tesla DOC-0015819 rev 1

for each step of the mfg process)

ssembly + Screwing station

duct
nt process inputs, value addition and output)

perations step by step.

dentify the nature of process:

t. Automatic material handling into and out of the station.
tomatic rejection of NG products.
h manual loading and unloading of the produt into the station.
tomatic rejection of NG products.
ading and unloading of the production into the station. Manual
allation/protective cap installation etc.)

this operation and their work instructions.

model, mfg year used in this operation.

ith tooling details: number of cavities, material, type of

peration and projected tool life.
 Internal #

RPM, CNC Spindle RPM, Brazing oven temperature,

m: field of view, resolution, accuracy.

Template

Subcomponent_Too
l_Equipmen
t_Tracker. xlsx

on (please clearly specify number of duplicate stations):

own of loading time, unloading time, inspection time and
r one unit
ing etc): Provide detailed breakdown of loading time,
e for one batch along with the batch size.

Template

Validation of
Capacity OEE.xlsm

Spec/Tolerance

2 of 2 (Hyperlinked)

BOM material must be mentioned in the BOM summary

ment, attach image for the barcode

sample verfication data. For. E.g. Torque/Angle,

images stored (example of the image)

Maintenance (PM).
schedule and checklist for each machine/tool

nt used in this operation. Spares need to kept to ensure

t of tooling, backup cameras, fixtures, robot, sensors,
tc.
 Internal #

Operation Template 1:
(Required for each process step, plea

Process Station Number 140

Image

Image of Process (including tool, equipment, machine)

(May use CAD model if not hard tooled yet)

Detailed description of operation steps

Process (100% Robotic, Semi-robotic, Manual)

Number of Operators required

Machine / Equipment Name and Model

Tooling
 Internal #

Equipment Parameters

Equipment/Tooling/Raw material Lead time

Cycle time per unit/per station

Expected OEE

Spec/Acceptance Criteria (Please enter the specification with the tolerances)

Error proofing detections for each step and frequency of inspection

BOM Material (Added / Removed)

Tracebility Grade#

Tracebility Data stored against sn#

Preventive Maintenance (PM) and Calibration of Equipment

(Please attach schedule daily/weekly/monthly/yearly and requirements)

Spare parts list for Equipment, Tooling

 Internal #

ation Template 1: Process DFM

(Required for each process step, please replicate the operation template page 1 and page 2 for each step of the mfg process)

Process Name Control station + Labeling + Final inspection

Image of product
(May use actual image or CAD model but must represent process inputs, value addition and output)

Provide detailed processes and operations step by step.

Following definitions should be used to identify the nature of process:

1. 100% Automatic process: Automatic processing of the product. Automatic material handling into and out of the station.
Automatic inspection of the product with automatic rejection of NG products.
2. Semi Automatic process: Automatic processing of the product with manual loading and unloading of the produt into the station.
Automatic inspection of the product with automatic rejection of NG products.
3. Manual process: Manual processing of the product with manual loading and unloading of the production into the station. Manual
inspection of the product. (e.g. wire harness installation/protective cap installation etc.)

Provide detailes on number of operator required for this operation and their work instructions.

Provide details of all machines/equipment name, model, mfg year used in this operation.

Provide details on the tooling required in this operation, along with tooling details: number of cavities, material, type of
operation, # of tooling per equipment/operation and projected tool life.
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Enter all equipment, and it's parameters. For e.g. Torque gun RPM, CNC Spindle RPM, Brazing oven temperature,
Force/Displacement parameters, vision system: field of view, resolution, accuracy.

1) Template attached (Follow the example in the template)

2) After the template is filled, save and attach the filled template in the next
row

Provide cycle time details for this operation. Cycle time per station (please clearly specify number of duplicate stations):
1. For single flow material/production: Provide detailed breakdown of loading time, unloading time, inspection time and
processing time for one unit
2. For batch production (E.g. Brazing, heat treatment, cleaning etc): Provide detailed breakdown of loading time,
unloading time, inspection time and processing time for one batch along with the batch size.

1) Use the template attached for the capacity. Fill out the 'Process Capacity
Study' Tab in the template for designed capacity (as per guidelines in the
template).
2) After the template is filled, save and attach the filled template in the next
row

Product feature/ Process parameter Spec/Tolerance

Complete Operation Template 2 of 2 (Hyperlinked)

Provide details on BOM material added/removed in this operation. BOM material must be mentioned in the BOM summary

Tracebility Grade as per design/SIE requirement, attach image for the barcode

Enter all process, tracebility including red-rabbit, master-sample verfication data. For. E.g. Torque/Angle,
displacement/force, temperature, dimensionals, images stored (example of the image)

Attach detailed Preventive Maintenance (PM).

-Daily/weekly/monthly/yearly preventive maintenance schedule and checklist for each machine/tool

Please provide list of all spare parts for the tooling and equipment used in this operation. Spares need to kept to ensure
continous production to meet Tesla EDI. For example: Extra set of tooling, backup cameras, fixtures, robot, sensors,
actuators, etc.
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Tesla DOC-0015819 rev 1

for each step of the mfg process)

+ Labeling + Final inspection

duct
nt process inputs, value addition and output)

perations step by step.

dentify the nature of process:

t. Automatic material handling into and out of the station.
tomatic rejection of NG products.
h manual loading and unloading of the produt into the station.
tomatic rejection of NG products.
ading and unloading of the production into the station. Manual
allation/protective cap installation etc.)

this operation and their work instructions.

model, mfg year used in this operation.

ith tooling details: number of cavities, material, type of

peration and projected tool life.
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RPM, CNC Spindle RPM, Brazing oven temperature,

m: field of view, resolution, accuracy.

Template

Subcomponent_Too
l_Equipmen
t_Tracker. xlsx

on (please clearly specify number of duplicate stations):

own of loading time, unloading time, inspection time and
r one unit
ing etc): Provide detailed breakdown of loading time,
e for one batch along with the batch size.

Template

Validation of
Capacity OEE.xlsm

Spec/Tolerance

2 of 2 (Hyperlinked)

BOM material must be mentioned in the BOM summary

ment, attach image for the barcode

sample verfication data. For. E.g. Torque/Angle,

images stored (example of the image)

Maintenance (PM).
schedule and checklist for each machine/tool

nt used in this operation. Spares need to kept to ensure

t of tooling, backup cameras, fixtures, robot, sensors,
tc.
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Inspection Description Dimension/Tolerance

Inspection Dimension/Tolerance
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Operation Template 2:
Inspection (In-process, Master sample verification)

Equipment: Vision System/ Error proofing

Red rabbit

Equipment: Vision System/ Error proofing

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Operation Template 2: Inspection

Inspection (In-process, Master sample verification)

Detection system description (vision sytem: model, description,

specs) Picture

Red rabbit

Detection system description (vision sytem: model, description,

specs) Picture
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ion

Inspection frequency Calibration Frequency

Inspection frequency Calibration Frequency

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Tesla DOC-0015819 rev 1

GRR Study (Please fill out the

template attached for each
gauge as per latest TS-13115)

TS-0003552-
R5_GRR.xlsx

GRR Study (Please fill out the

template attached for each
gauge as per latest TS-13115)
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