Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan

Chapter 7 Quality Section
March 2008 Revision 1.0

1444481

Document #:
Program:
Model Year:

Template - Peel and Stick Heater Control Plan

RFQ # / Basis #:
Back Office Chief / Manager
Back Office Lead
Program Manager
Phase:
ECO #:

Rev:
A

N/A
N/A
Deana Borghi
Joe Hebda
Robert Hicks
N/A
Change Description:
Initial Release

Date:

Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan
Chapter 7 Quality Section
March 2008 Revision 1.0

Control Plan Form Instructions

Responsibility
The Quality Manager is responsible for defining the control methods and the reaction plan, and approving and
maintaining the Control Plan for the system or subsystem (i.e., Components, etc) level product manufactured
at the AG plant.
The Product Engineer is responsible for delivering the information about the part number and description, the
product and process characteristics, the significant and critical (SC/CC), and the Design Failure Mode and
Effects Analysis (DFMEA) results where they relate to the Control Plan.
The Manufacturing Engineer is responsible for delivering PFMEA and the process steps and description
information.

Prototype
ControlPlanNumber
PartNum
ber/L
atestChangeLevel

ControlPlan

Pre-launch

Production K
eyContact/Phone
CoreTeam

PartN
am
e/D
escription
Supplier/Plant
Part/
Process
Number

SupplierCode
ProcessName/
Operation
D
escription

M
achine,Device,
Jig,Tools N
o.
ForM
fg.

Date(Orig.)
D
ate(Rev.)
Custom
erEngineeringApproval/Date(IfReq'd)

Supplier/PlantApproval/Date

Custom
erQualityAproval/Date(IfReq'd)

OtherApproval/Date(IfReq'd)

OtherAproval/Date(IfReq'd)

Characteristics
Process
Product

Special
Char.
Product/Process
Class. Specification/Tolerance

M
ethods
Evaluation
Sam
ple
M
easurem
ent
Technique Size Freq.

ControlM
ethod Reaction
Plan

Def ines scope of

inspect ions

Control of
nonconforming
products

Incoming

DVP

In-process

Audit
Final

Process flow
diagram,
PFMEA

DFMEA,
PFMEA

SC/CC

Def ines scope of MSA

St atistical techniques

Instruction:
The AQE/QE develops a Control Plan taking into consideration all requirements applicable to the system or
subsystem (I.e. , Components, etc) level product manufactured at the AG plant.
The AQE/QE must review the FMEA forms to identify the necessary controls.
Special consideration must be given to Critical and Significant characteristics
The Control Plan form has 3 distinct forms that must be completed at the required phase in the PLUS process:
DV Build Control Plan: completed to support the development of prototype builds.
Pre-launch Control Plan: completed after the Prototype Control Plan with the introduction of saleable vehicle
builds made from production tools; used until all customer and AG requirements are met.
Production Control Plan: Provided with Customer Part Submission and becomes effective upon customer
approval.
The above Control Plans must include/identify all known Customer Special Characteristics, AG internal
Special Characteristics and Safety/Regulatory requirements (i.e., All SCs and CCs).
applicable to the system or subsystem (i.e., Components, etc) level product manufactured at the AG plant.
Customer SC/CCs, including those controlled at suppliers, must be addressed in the control plan.
AG SC/CCs controlled in the manufacturing process must be addressed in the control plan.
Note: System or subsystem level SC/CCs may be controlled at internal or external supplier/s.
In this case, the AQE should complete all fields on the Control Plan up to and including the Evaluation Method field.
A suggested reference in the Evaluation Method through Reaction Plan fields would be , "See Supplier Control Plan/s".

Continuous Compliance Test (CCT) requirements are reflected in the Control plan or the control plan may
refer to the DVP&R for CCT requirements.
Customer specific requirements, such as annual dimensional lavout, shall be identified on the Control Plan.
Refer to the Control Plan Example tab in this document for examples of the above requirements.
For Customer / Component BU within the scope of VDA:
Note that the Control Plan shall be identified with "A" in the top right corner whenever there is
at least 1 critical characteristic mentioned. This identification is required to highlight special
archiving requirement (eg. 15 years) for this document. See VDA 1 brochure for details.
Records / Logs
The Control Plan is stored by the Quality Manager.
References
Advanced Product Quality Planning and Control Plan (AIAG reference manual)
Characteristic Management standard (WW-PLUS-ST-02-01)
WW-PLUS-FR-02-01-E / Rev 08 (01-October-2004)

Page 2 of 6

Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan
Chapter 7 Quality Section
March 2008 Revision 1.0

Control Plan
DV Build

Pre-launch

Production

Key Contact/Phone

Date (Orig.)

Date (Rev.)

Core Team

Customer Engineering Approval/Date (If Req'd)

Control Plan Number

Part Number/Latest Change Level

Seat Heater team

Part Name/Description

Supplier/Plant

Supplier Code

Part /

Process Name /

Machine, Device,

Process

Operation

Jig, Tools

Number

Description

Supplier/Plant Approval/Date

Customer Quality Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Characteristics
No.

For Mfg.

Product

Special
Process

Methods

Char.

Product / Process

Evaluation

Class.

Specification/Tolerance

Measurement
Technique

Sample

Control Method

Reaction
Plan

Size

Freq.

Operator responsibilities
Stock seat heater at
correct station on
assembly line

assure correct
part number per
ODS

each
container

visual
management

Remove
incorrect
product
from line.

Remove seat heater

assembly from
container without stress
on wire harness

Use handling
technique which
does not stress
harness, per
ODS

each
assembly

visual
management

Aside units
handled
improperly
for
disposition

Post assembly, assure

heater is in correct
position

assure position
of heater on
cover meets
requirements of
ODS

each
assembly

visual
management,
template

Aside
assemblies
positioned
improperly
for
disposition

post assembly, assure

adhesive backing tape
is removed

visually check
each adhesive
area such that
the appropriate
color is showing
in the tape
windows

each
assembly

visual check

Aside
cushion
assemblies
which do
not meet
criteria

assure no foreign
objects traped under
heater post assembly to
pad

run hand over

heater to detect
foreign objects

each
assembly

manual check

Aside
assemblies
with poor
adhesion to
the pad for
disposition

Check visually
to print and
ODS

Remove seat heater

assembly from
container without stress
on wire harness

Use handling
technique which
does not stress
harness per
ODS

observe
handling
technique used

Post assembly, assure

heater is in correct
position

assure position
of heater on
cover meets
requirements of
ODS within +/10 mm

WW-PLUS-FR-02-01-E / Rev 08 (01-October-2004)

once per job rotation

assure correct
part number per
ODS

5 consecutive assemblies

Stock seat heater at

correct station on
assembly line

scale

ontact supervisor who mus correct operation, quarrentine all product built
since last succcessful audit for verification.

Auditor responsibilities

Page 3 of 6

Machine, Device,

Operation

Jig, Tools

Number

Description

Characteristics
No.

For Mfg.

post assembly, assure

adhesive tape backing
has been removed

assure no foreign
objects traped under
heater post assembly to
pad

WW-PLUS-FR-02-01-E / Rev 08 (01-October-2004)

Product

Special
Process

Methods

Char.

Product / Process

Evaluation

Class.

Specification/Tolerance

Measurement
Technique

correct color
shows in tape
windows

run hand over

heater to detect
foreign objects

Size

Sample

Control Method

Stop operation, contact supervisor who mus correct operation, quarrentine

since last succcessful audit for verification.

Process Name /

once per job rotation

Part /
Process

5 consecutive assemblies

Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan
Chapter 7 Quality Section
March 2008 Revision 1.0

Reaction
Plan

Freq.

visual check

manual check

Page 4 of 6

Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan
Chapter 7 Quality Section
March 2008 Revision 1.0

Control Plan - Example

DV Build

Pre-launch

Production

Key Contact/Phone

Date (Orig.)

Date (Rev.)

Part Number/Latest Change Level

Core Team

Customer Engineering Approval/Date (If Req'd)

Part Name/Description

Supplier/Plant Approval/Date

Customer Quality Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Control Plan Number

Supplier/Plant

Supplier Code

Part /

Process Name /

Machine, Device,

Process

Operation

Jig, Tools

Number

Description

For Mfg.

Characteristics
No.

Product

Special
Process

Methods

Char.

Product / Process

Evaluation

Class.

Specification/Tolerance

Measurement
Technique

Sample
Size

Control Method

Reaction

Freq.

Plan

A) Control at Supplier
Option 1) System/Subsystem level SC/CC Controlled at a Component/Part SC/CC Level at Multiple Suppliers
Option 1a)
All
effected
parts-see
list

Receiving

Flammability:
FMVSS 302

CC

Per FMVSS 302

See Supplier
Control Plans

See
Supplier
Control
Plans

Annual Supplier
PPAP/Recertifcation

FMVSS 201

CC

Per FMVSS 201

Suppliers
PPAP/Cert
Review

Each LF
part see list

See
Supplier Control
Supplier Plans
Control
Plans

See
Supplier
Control
Plans

Option 1b)
All
effected
parts-see
list

Annual

Annual Supplier
PPAP/Recertific
ation. Review
PPAP.

Follow
Corrective
Action
procedure

Option 2) System/Subsystem level SC/CC Controlled at a Component/Part SC/CC Level at Multiple/or Single Supplier/s.
This would be used a) If you choose to list all Supplier SC/CC's in the control plan b) To highlight the key SC/CC components.
Option 2a)
Cushion
foam Part
# abcdefg

Receiving

FMVSS 202

SC

Foam ILD

See Supplier
Control Plan

See
Supplier
Control
Plan

Annual Supplier
PPAP/Recertifcation

FMVSS 201

CC

Per FMVSS 201

PPAP/Cert
Review

1
Package

See
See Supplier
Supplier Control Plan
Control
Plan

See
Supplier
Control Plan

Option 2b)
Part # 123

Annual

Annual Supplier
PPAP/Recertific
ation. Review
PPAP.

Follow
Corrective
Action
procedure

(Optional) Highlight Control of a Key JCI Identified Supplier SC/CC at a Supplier (not a System/Subsystem Characteristic) This would be used to highlight a key SC/CC on components.
Plastic
Part #
12345

Receiving

Part Length

SC

30mm +/- 2mm

See Supplier
Control Plan

See
Supplier
Control
Plan

Material
Specification ABC

CC

Must meet spec DCE

Incoming
Inspection

1 Cert

SC

24 NM +/- 4NM

Torque
Monitoring
System
Controller

100%

Shipping Positon

SC

Seat Angle 30Deg +/-5 Station 17

deg
lasers

100%

SC1, SC2 SC3,

SC4

SC

Perimeter Inspection
checklist +10mm/10mm

See
See Supplier
Supplier Control Plan
Control
Plan

See
Supplier
Control Plan

B) Control at AG Plant
Incoming Inspection
Seq
Number/
Etc

Incoming Inspection

Each Lot Review Supplier Return to

Certification
Supplier

Assembly Process
Process #

Marriage of back to
track assembly

Bolt Torque

Atlas Copco Torque

Driver Torque
Monitoring

100%

Atlas Copco

Follow
Corrective
action plan
on ODS

Final Inspection
Station 15 Set-up Shipping position

Station P

Indexing
Build fixture

Dimensional inspection Overhead

System
Check
fixture
Periodic Checks

Overhead
System Check
fixture

Continuo Automated
us
Inspection

Part not
released.
Following
NC
Material/Re
work
procedure

Per Shift Check Sheets

Follow
Corrective
Action plan
on ODS

(at JCI)

WW-PLUS-FR-02-01-E / Rev 08 (01-October-2004)

Page 5 of 6

Supplier Standards Manual

Seat Heat Peel and Stick Heater Control Plan
Chapter 7 Quality Section
March 2008 Revision 1.0

Control Plan - Example

DV Build

Pre-launch

Production

Key Contact/Phone

Date (Orig.)

Date (Rev.)

Part Number/Latest Change Level

Core Team

Customer Engineering Approval/Date (If Req'd)

Part Name/Description

Supplier/Plant Approval/Date

Customer Quality Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Other Approval/Date (If Req'd)

Control Plan Number

Supplier/Plant

Supplier Code

Part /

Process Name /

Machine, Device,

Process

Operation

Jig, Tools

Number

Description

For Mfg.

Characteristics
No.

Dimensional inspection Overhead

System
Check
fixture

Product

Special
Process

Methods

Char.

Product / Process

Evaluation

Class.

Specification/Tolerance

Measurement
Technique

Sample

Control Method

Size

Freq.

Reaction
Plan

Surface Contour
points A-F

SC

Perimeter Inspection
checklist +10mm/10mm

CMM

Annual

Layout
Inspection
Record

Follow
Corrective
Action
procedure

Continuous Compliance
Testing - Visor Assembly

Flammability:
FMVSS 302

CC

Per FMVSS 302

Laboratory Test

Annual

Continuous
Compliance
Testing

Follow
Corrective
Action
procedure

Continuous Compliance
Testing - Console
Assembly

Flammability:
FMVSS 201 and
302

CC

See DVP&R

See DVP&R

See
DVP&R

Annual

Continuous
Compliance
Testing

Follow
Corrective
Action
procedure

WW-PLUS-FR-02-01-E / Rev 08 (01-October-2004)

Page 6 of 6