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QS9000FORMS1WORKBOOKV20ACOPYRIGHT1998,1999,2000MARCHQUALITYSERVICESPARTNAMENAMEPARTNUMBERNUMBERENGINEERINGCHANGELEVELECLENGINEERINGCHANGELEVELDATEECLDATESUPPLIERNAMESUPPLIERSUPPLIERCODECODESTREETADDRESSADDRESSCITYCITYSTATESTATEZIPZIPPHONENUMBER5555555555CUSTOMERNAMEGMDIVISIONDIVISIONAPPLICATIONAPPLICATIONFILENAMEFILEXLSFORSALESANDTECHNICALSUPPORTCONTACTCARWINLTDTEL4401708861333/ORFAX867941TRANSLATIONENGLISHGERMANDOCUMENTEDITIONPRINTINGADVANCEDPRODUCTQUALITYPLANNINGANDCONTROLPLANREFERENCEMANUALFIRSTFEB95MEASUREMENTSYSTEMANALYSISSECONDJUN98POTENTIALFAILUREMODEANDEFFECTSANALYSISSECONDFEB95PRODUCTIONPARTAPPROVALTHIRDFEB00THEFOLLOWINGLEVELSOFDOCUMENTSWEREUSEDTOPREPARETHISWORKBOOKA1DESIGNFMEACHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATE1WASTHESFMEAAND/ORDFMEAPREPAREDUSINGTHEDAIMLERCHRYSLER,FORD,ANDGENERALMOTORSPOTENTIALFAILUREMODEANDEFFECTSANALYSISFMEAREFERENCEMANUAL2HAVEHISTORICALCAMPAIGNANDWARRANTYDATABEENREVIEWED3HAVESIMILARPARTDFMEASBEENCONSIDERED4DOESTHESFMEAAND/ORDFMEAIDENTIFYSPECIALCHARACTERISTICS5HAVEDESIGNCHARACTERISTICSTHATAFFECTHIGHRISKPRIORITYFAILUREMODESBEENIDENTIFIED6HAVEAPPROPRIATECORRECTIVEACTIONSBEENASSIGNEDTOHIGHRISKPRIORITYNUMBERS7HAVEAPPROPRIATECORRECTIVEACTIONSBEENASSIGNEDTOHIGHSEVERITYNUMBERS8HAVERISKPRIORITIESBEENREVISEDWHENCORRECTIVEACTIONSHAVEBEENCOMPLETEDANDVERIFIEDREVISIONDATEPREPAREDBYPAGE4OF87A2DESIGNINFORMATIONCHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATEAGENERALDOESTHEDESIGNREQUIRE1NEWMATERIALS2SPECIALTOOLING3HASASSEMBLYBUILDVARIATIONANALYSISBEENCONSIDERED4HASDESIGNOFEXPERIMENTSBEENCONSIDERED5ISTHEREAPLANFORPROTOTYPESINPLACE6HASADFMEABEENCOMPLETED7HASADFMABEENCOMPLETED8HAVESERVICEANDMAINTENANCEISSUESBEENCONSIDERED9HASTHEDESIGNVERIFICATIONPLANBEENCONSIDERED10IFYES,WASITCOMPLETEDBYACROSSFUNCTIONALTEAM11AREALLSPECIFIEDTESTS,METHODS,EQUIPMENTANDACCEPTANCECRITERIACLEARLYDEFINEDANDUNDERSTOOD12HAVESPECIALCHARACTERISTICSBEENSELECTED13ISBILLOFMATERIALCOMPLETE14ARESPECIALCHARACTERISTICSPROPERLYDOCUMENTEDBENGINEERINGDRAWINGS15HAVEDIMENSIONSTHATAFFECTFIT,FUNCTIONANDDURABILITYBEENIDENTIFIED16AREREFERENCEDIMENSIONSIDENTIFIEDTOMINIMIZEINSPECTIONLAYOUTTIMEPAGE5OF87A2DESIGNINFORMATIONCHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATE17ARESUFFICIENTCONTROLPOINTSANDDATUMSURFACESIDENTIFIEDTODESIGNFUNCTIONALGAGES18ARETOLERANCESCOMPATIBLEWITHACCEPTEDMANUFACTURINGSTANDARDS19ARETHEREANYREQUIREMENTSSPECIFIEDTHATCANNOTBEEVALUATEDUSINGKNOWNINSPECTIONTECHNIQUESCENGINEERINGPERFORMANCESPECIFICATIONS20HAVEALLSPECIALCHARACTERISTICSBEENIDENTIFIED21ISTESTLOADINGSUFFICIENTTOPROVIDEALLCONDITIONS,IE,PRODUCTIONVALIDATIONANDENDUSE22HAVEPARTSMANUFACTUREDATMINIMUMANDMAXIMUMSPECIFICATIONSBEENTESTED23CANADDITIONALSAMPLESBETESTEDWHENAREACTIONPLANREQUIRESIT,ANDSTILLCONDUCTREGULARLYSCHEDULEDINPROCESSTESTS24WILLALLPRODUCTTESTINGBEDONEINHOUSE25IFNOT,ISITDONEBYANAPPROVEDSUBCONTRACTOR26ISTHESPECIFIEDTESTSAMPLINGSIZEAND/ORFREQUENCYFEASIBLE27IFREQUIRED,HASCUSTOMERAPPROVALBEENOBTAINEDFORTESTEQUIPMENTDMATERIALSPECIFICATION28ARESPECIALMATERIALCHARACTERISTICSIDENTIFIED29ARESPECIFIEDMATERIALS,HEATTREATANDSURFACETREATMENTSCOMPATIBLEWITHTHEDURABILITYREQUIREMENTSINTHEIDENTIFIEDENVIRONMENT30ARETHEINTENDEDMATERIALSUPPLIERSONTHECUSTOMERAPPROVEDLISTPAGE6OF87A2DESIGNINFORMATIONCHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATE31WILLMATERIALSUPPLIERSBEREQUIREDTOPROVIDECERTIFICATIONWITHEACHSHIPMENT32HAVEMATERIALCHARACTERISTICSREQUIRINGINSPECTIONBEENIDENTIFIEDIFSO,33WILLCHARACTERISTICSBECHECKEDINHOUSE34ISTESTEQUIPMENTAVAILABLE35WILLTRAININGBEREQUIREDTOASSUREACCURATETESTRESULTS36WILLOUTSIDELABORATORIESBEUSED37AREALLLABORATORIESUSEDACCREDITEDIFREQUIREDHAVETHEFOLLOWINGMATERIALREQUIREMENTSBEENCONSIDERED38HANDLING39STORAGE40ENVIRONMENTALREVISIONDATEPREPAREDBYPAGE7OF87A3NEWEQUIPMENT,TOOLING,ANDTESTEQUIPMENTCHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATEDOESTHEDESIGNREQUIRE1NEWMATERIALS2QUICKCHANGE3VOLUMEFLUCTUATIONS4MISTAKEPROOFINGHAVELISTSBEENPREPAREDIDENTIFYING5NEWEQUIPMENT6NEWTOOLING7NEWTESTEQUIPMENTHASACCEPTANCECRITERIABEENAGREEDUPONFOR8NEWEQUIPMENT9NEWTOOLING10NEWTESTEQUIPMENT11WILLAPRELIMINARYCAPABILITYSTUDYBECONDUCTEDATTHETOOLINGAND/OREQUIPMENTMANUFACTURER12HASTESTEQUIPMENTFEASIBILITYANDACCURACYBEENESTABLISHED13ISAPREVENTIVEMAINTENANCEPLANCOMPLETEFOREQUIPMENTANDTOOLING14ARESETUPINSTRUCTIONSFORNEWEQUIPMENTANDTOOLINGCOMPLETEANDUNDERSTANDABLE15WILLCAPABLEGAGESBEAVAILABLETORUNPRELIMINARYPROCESSCAPABILITYSTUDIESATTHEEQUIPMENTSUPPLIERSFACILITY16WILLPRELIMINARYPROCESSCAPABILITYSTUDIESBERUNATTHEPROCESSINGPLANT17HAVEPROCESSCHARACTERISTICSTHATAFFECTSPECIALPRODUCTCHARACTERISTICSBEENIDENTIFIEDPAGE8OF87A3NEWEQUIPMENT,TOOLING,ANDTESTEQUIPMENTCHECKLISTCUSTOMERORINTERNALPARTNONUMBERQUESTIONYESNOCOMMENT/ACTIONREQUIREDPERSONRESPONSIBLEDUEDATE18WERESPECIALPRODUCTCHARACTERISTICSUSEDINDETERMININGACCEPTANCECRITERIA19DOEST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