CONTROL PLAN REVISION APPROVED REVIEWED DRAFTED

MODEL Radio Harnesses CODE PC-A-A-F-01

14
DISTRIBUTION OF COPIES
CHANGE HISTORY

AREA NAME
REVISION DATE CONTENT OF THE CHANGE Page Rev. Reviewed by

12 4/18/2012 Process Class Evaluation Gonzalo Brborich N/A N/A Gerencia de Planta N/A

13 2/20/2013 Change of format, change in processes considered with self-inspection and change in symbolism. Christian Chimbo C F Production Christian Rivadeneira

14 6/17/2013 Inclusion of harness Model RT50 and Subproduct Harness Interface RT50 (SA-RT50) Christian Chimbo O E Engineering Christian Chimbo

Process Control Plan Development Team

Area Name Company

QA Edison Pazmiño

ING Cristian Ligña

ING Christian Chimbo

PROD. Christian Rivadeneira

Maintenance Gonzalo Lasso

FO-DD-28 Review 0 Valid since 09.08.12 Rev. [Link]. Approved. GP

 Page 2 of 11
CONTROL PLAN PC-A-A-F-01

CONTROL PLAN PC-A-A-F-01 LINE: HARNESS DATE OR

SUPPLIER/PLANT: Mundy Home Harnesses PROCESS: Harness Manufacturing DATE RE
SUPPLIER CODE 935120522 DEPARTAMENTO:Producción
CLIENT APPROVED ENGINEER
FROM/Last change:52042855 AREAS INVOLVED: Warehouse, Production, QA
Date
NAME OF THE PART: Radio Harness KEY CONTACT: [Link]
AÑO / MODELO:2013 TELEFONO:(593) 2 800 351
APPROVED. CLIENT QUALITY /
PLANNING TEAM: G. Brborich, C. Chimbo, E. Pazmiño, C. Ligña, C. Rivadeneira Internal Approval

Characteristics Methods
Process Tool or Samples
Process Description Operation Description Specifications and Method of
Number Machine No Product Process Class Analysis/Control Method Func
Tolerances Measurement Size Frequency

Equal physical quantities

100-1 Manufacturing Order Visual 100% C/OF Manufacturing Order Op.
to the manufacturing order

Materials according to
Containers, 100-2 the specified in the Warehouse Layout Visual 100% C/OF 5S Audit Op.
Prepare the materials Rule manufacturing order
Preparation of
100 necessary, according to the Device of Specification of
material Integrity of the insurance in
product to be manufactured cut of 97 Processes by Model Visual 100% C/F 100% visual inspection Op.
Mangas original connector
Bodega

Specification of
100% visual inspection of
100-5 Harness without tether Processes by Model Visual 100% C/OF according to the Manufacturing Order
Op.
Warehouse

Cutting length of
agreement to Sheet Specification Sheet
115-1
Cut Specification and
PQC of Cutting and Peeling
{"text":"Measuring tape"}
3 C/OF Control Letter Op
Bald

Length of peeling of
agreement to Sheet of Specification Sheet Release registry of
115-2 Calibrator 1 C/Tuning
Cutting Specification and of Cutting and Peeling machines
Bald

Cut and peeled of Cut and strip the wires of Machine Integrity of insulator in Release log of
115-3 Visual Help Visual 1 C/Tuning
cables in machine according to the Sheet of KOMAX, rule, all the cable machines
115
peeler-cutter Cutting specifications and tape measure
automatic peeled calibrator Cables with stripping Release registry of
115-4 partial of the insulator
Visual Aid Visual 1 C/Adjustment
machines

Thread Integrity of Release record of

115-5 Visual Help Visual 1 C/Tuning
Copper machines
Cut cables with 100% Inspection
115-6 Visual Help Visual 100% C/O Op
identification 5 S´s Audit
Set up machine
Specification Sheet
115-A peeling cutter of Cutting and Peeling
Visual 1 C/Tuning First Piece Inspection
automatic

Place the product Cantidad de producto Pre-count according to Order of

950-1 Manufacturing Order Visual 100% C/O Op.
approved in the Containers, the same as reported Manufacturing
Storage of
950 locations car of
Approved product Approved product
corresponding in the products
Wine cellar 950-2 located in the area Warehouse Layout Visual 100% C/OF 5 S's Audit Op.
designated in warehouse

Cut Length of
according to the Sheet of Cutting specifications
140-1
Cutting specifications
PQC by model
Rule 3 C/OF Control Letter Up
Cut the cables of the harness Rule
Manual cutting of by model
original according to the Refrigerator
140 harness cables
cutting specifications Cutter of
original Cut cables from
by model cables
according to the Sheet of Cutting specifications
140-2 Visual 100% C/OF 100% Inspection On
Cutting specifications by model
 Features Methods
Process Tool or Samples
Process Description Operation Description Specifications and Method of
Number Machine No Product Process Class Analysis/Control Method Func
Tolerances Measurement Size Frequency

Length of peeling of
according to the Sheet of Specification sheet
150-1
specifications of PQC of Bald
Calibrator 3 C/OF Control Letter Op
Carry out the stripping of Bald
each of the cables of Peeler
Semi-automatic peeler
150 recovered to the sheet of Pneumatics, Integrity of threads
of cables 150-2 Complete copper wires Visual 100% C/OF 100% Inspection Op
peeling specifications Caliper copper
by model
Peeler setup IT for fine-tuning of Release record of
150-A Visual 3 C/Tuning
semiautomatic Pneumatic Peeling Machines machines

Length of peeling of
Specification sheet
155-1 agreement to Sheet of PQC of Bald
Calibrator 3 C/OF Control Letter
Peeling Specification

Perform the stripping of Thread integrity of

155-2 Complete copper wires Visual 100% C/OF First Unit Inspection
each of the cables of Peeler copper
Manual peeler of
155 according to the sheet of manual
cables
peeling specifications Calibrator Integrity of the insulator of Complete insulator in
by model 155-3 Visual 100% C/O First Unit Inspection On
cable all the cable

Peeling machine setup IT tuning of Release log of

155-A Visual 3 C/Calibration
manual manual peelers machines
 Characteristics Methods
Process Tool or Muestras
Description of the Process Operation Description Specifications and Method of
Number Machine No Product Process Class Analysis/Control Method Func
Tolerancias Measurement Size Frequency

Use of terminal Specifications of

164-1 Visual 100% C/O 100% Inspection Op
corresponding Reworked by Model

Liberation of
Riveted cables with Press
Inspection form Tester Release log of
164-2 resistance to tension of 5 Riveter and
terminal reconditioning WTT-110 machines
agreement to specification Every 1000
Reworked

Reinforced cables with Liberation of

height and width of Press
Inspection sheet Release registry of
164-3 barrel terminals of Micrometer 1 Rehammer and
terminal remachining machines
copper according to the Every 1000
Pitu Presses
Fix terminals specification. Reworked
Press
Reworked from corresponding in the
ZETA
164 terminals with peeled extremes of the Cables riveted with
Applicators,
applicator cables with the help of a height and width of
Pull tester Inspection form Release record of
riveting press. 164-4 barrel terminals of Micrometer 5 C/Tuning
micrometer terminal remachining machines
insulator according to the
specification.

Physical Appearance (State

according to the terminal
164-5 Visual aids Visual 100% C/OF 100% Inspection Op
the criteria of
remachado.

Cables with terminals Specifications of

164-6 Visual 100% C/O 100% Inspection Op
remachados Reworked by Model
Setup of the Presses and
IT Tuning of
164-A applicators for Visual 3 C/Setting Up First Piece Inspection
Presses and Applicators
reworked

Use of terminal Specifications of

155-1 Visual 100% C/OF 100% Inspection Op
corresponding Rematched by Model

Fix terminals Liberation of

corresponding in the Riveter Riveted cables with Press
Manual Rework Inspection Form Tester Release record of
172 peeled extremes of the manual 155-2 tensile strength of 5 Reworker and
Terminals terminal remachado WTT-110 machines
cables with the help of a Calibrator agreement to specification Every 1000
manual remanufacturer. Remachados
Physical Appearance (Condition
from the terminal) according to
155-3 Visual aids Visual 100% C/OF 100% Inspection Op
the criteria of
remachado.
Cable positioning inside
of the connector in the
Crimp the cables cavities Specification of
repaired inside the 180-1 Visual 100% C/OF 100% Inspection Op
Devices of corresponding of Connections by model
connector, in the cavities according to the Sheet of
180 Armed armed
corresponding from Connections
according to the Sheet of
(Glove)
Connections
Terminal crimping Specification of
178 Visual 100% C/OF 100% Inspection On
in connector Connections by model.

Hold the cables by Harness entailed according to

the tape covering Specification sheet
188 Entitled Scissors 188-1 specification sheet Rule 100% C/OF 100% Inspection On
taipe to shape the by model upholstery
of model out of shape
harness
Automatic verification
Continuity of
192-1
Correct connections
AQC of continuity between CIRRIS 100% C/OF 100% Inspection Op
correct connections

Boards of Terminal crimping

192-2 Visual Aid Visual 100% C/OF 100% Inspection On
Electrically test the equipment, tests in connector
Electrical test of
192 continuidad y conformidad CIRRIS,
 Characteristics Methods
Process Tool or Samples
Description of the Process Operation Description Specifications and Method of
Number Machine No Product Process Class Analysis/Control Method Func
Tolerances Measurement Size Frequency
192 continuity and compliance CIRRIS,
100% of the product
of the connections MemoryToken Terminal crimping to
Standard samples 192-3 original connector
Visual Help Visual 100% C/OF 100% Inspection Up

Tuning of the IT tuning of

192-A test board test board Visual 1 C/Tuning Tuning Registration On
electric electric
Presence of tape
Specification sheet
196-1 foam in the Visual 100% C/O 100% Inspection Op
of encasing
Put foam tape and designated connectors
label on the connectors
designated according to Foam love guaranteed Specification sheet
196 Encasement Scissors 196-2 Visual 100% C/OF 100% Inspection Op
the sheet of with tape of encasement
specifications of
encapsulation
Presence of label in Specification sheet
196-3 Visual 100% C/OF 100% Inspection Up
the product of encasing

Amounts to 100% of
918-1 inspect according IT of the Sampling Plan Visual the C/O 100% inspection of samples
the sampling plan samples
Verify by sampling 100% of
Visual inspection of Compliance with Specifications of
918 compliance with None 918-2 Visual the C/OF 100% inspection of the samples
samples for QA specifications Connections by model
specifications samples

Application of the plan of

100% of
918-A Final inspection IT Visual the C/OF 100% inspection of the samples
sampling
samples
 Characteristics Methods
Process Tool or Samples
Process Description Operation Description Specifications and Method of
Number Machine No Product Process Class Analysis/Control Method Func
Tolerances Measurement Size Frequency

Automatic verification 100% of

Continuity of
193-1 of continuity between CIRRIS the C/OF 100% inspection of the samples
Correct connections
correct connections samples
100% of
Terminal crimping
193-2 Visual Help Visual the C of 100% inspection of the samples
in connector
samples
Boards of
Electrically test the
Electrical test of Test, equipment 100% of
continuity and conformity Terminal crimping to
193 100% of the samples from the connections to the
CIRRIS, 193-3 Visual Aid Visual the C/OF 100% inspection of the samples
original connector
of QA MemoryToken samples
QA samples
Standard samples
100% of
Worksheet
193-4 Visual the C/OF 100% inspection of the samples
Standardized
samples
Tuning of the IT setup of
193-A test board test board Visual 1 C/Tuning Tuning Registration Op
electric electric

Approval of the batch of Define the status of the batch State identification Precount
922 None 922-1 Lote aprobado Visual 1 C/OF
manufacturing inspected of inspection 5 S's Audit

Place the product Quantity of product Pre-count according to

950-1 Visual 100% C/OF Manufacturing Order Op.
approved on the Containers, same as reported Manufacturing Order
Storage of
950 locations car of
Approved product Approved product
corresponding in the products
Grocery store 950-2 located in the area Warehouse Layout Visual 100% C/OF 5 S's Audit Op.
designated in warehouse

Correct amounts of
970-1 Delivery Note Visual 100% C/O 100% Inspection Op.
delivery

Product is delivered to
Delivery of product to IT of conservation of
970 Deliveries Containers 970-2 Plant Radios without damage Visual 100% C/OF 100% Inspection Op.
radio plants Product
in transport

Defined containers
970-A Visual Aid Visual 100% C/OF 100% Inspection Op.
by models

VEHICLE MODEL Identification Number

Various
 Page 7 of 11
Prototype
Pre-launch
Production x
18-Sep-06 REV: 14
EVISION: June 17, 2013

RIVER

Date

Reaction Plan / Corrective Action

ion Resp. Parameters

Store OK - No OK Material Recount

Bodega OK- No OK Carry out 5 S's

Segregate, identify and inform the

Store OK - No OK
QA Supervisor

Segregate, identify, and inform to

Bodega OK - No OK
QA Supervisor

perario OK- No OK Machine Recalibration

QA OK- No OK Reassemble the blades

Verification of nozzle status by

QA OK- No OK the Maintenance Supervisor.

Verification of Nozzle Status by

QA OK- No OK the Maintenance Supervisor

Verification of nozzle status by

QA OK- No OK the Maintenance Supervisor.

Segregate, identify and inform the

perario OK- No OK
Production Supervisor

QA OK- No OK Repeat machine setup

Bodega OK - No OK Material Recount

Store OK- No OK Perform 5 S's

Segregate, identify and inform to

perario OK- No OK
Production Supervisor

Segregate, identify, and inform the

perario OK- No OK
Production Supervisor
 Reaction / Corrective Action Plan
Response Action Parameters

Segregate, identify and inform the

OK- No OK
Production Supervisor

Segregate, identify, and inform the

perario OK- No OK
Supervisor de Producción

QA OK - No OK Repeat machine setup

QA OK- No OK Repeat machine setup

QA OK- No OK Repeat machine setup

perario OK- No OK Repeat machine setup

QA OK- No OK Repeat machine setup

 Reaction Plan / Corrective Action
Response Action Parameters

Segregate, identify, and inform the

perario OK - No OK
Production Supervisor

QA OK- No OK Repeat machine setup

QA OK- No OK Repeat machine setup

QA OK- No OK Repeat machine setup

Segregate, identify, and inform the

perario OK - No OK
Production Supervisor

Separate, identify and inform the

perario OK- No OK
Production Supervisor

QA OK- No OK Repeat machine setup

Segregate, identify and inform

perario OK- No OK
Production Supervisor

QA OK- No OK Repeat machine setup

Segregate, identify, and inform the

perario OK- No OK
Production Supervisor

Segregate, identify and inform the

perario OK - No OK
Production Supervisor

situation OK - Not
Segregate, identify and inform the
OK
Production Supervisor

Segregate, identify and inform the

perario OK- No OK
Production Supervisor

Repeat the test board setup

perario OK- No OK
electric

Segregate, identify and inform the

OK- No OK
Production Supervisor
 Reaction Plan / Corrective Action
Resp. Parameters

Segregate, identify and inform to

perario OK- No OK
Production Supervisor

Segregate, identify and inform to

perario OK- No OK
Production Supervisor

Segregate, identify and inform the

perario OK- No OK
Production Supervisor

Segregate, identify, and inform the

perario OK- No OK
Production Supervisor

Segregate, identify, and inform the

perario OK- No OK
Production Supervisor

Segregate, identify and inform to

QA OK- No OK
Quality Supervisor

Segregate, identify and report to

QA OK- No OK
Quality Supervisor

Segregate, identify and inform the

QA OK - No OK
Quality Supervisor
 Reaction Plan / Corrective Action
Resp. Parameters

Repeat test board setup

QA OK- No OK
electric

Segregate, identify and inform the

QA OK- No OK
Production Supervisor

Segregate, identify and inform to

QA OK- No OK
Production Supervisor

Segregate, identify, and report to the

QA OK- No OK
Production Supervisor

Repeat test board setup

perario OK- No OK
electric

QA OK- No OK Re-inspection

Bodega OK - Not OK Material Recount

Bodega OK- No OK Implement 5 S's

Segregate, identify, and inform the

Bodega OK - Not OK
Production Supervisor

Segregar, identificar e informar al

Bodega OK - Not OK
Production Supervisor

To segregate, identify, and inform the

Store OK - No OK
Production Supervisor