Sscaf

1.
DFMEA and
potential special Type ONLY in Yellow Boxes
characteristics
Lead / Support roles and

Ford PD engineer / Supplier
timing for each stage
Program: 2018 U554 Front Door trim End Item Assembly
Supplier Name/Plant: Faurecia, Saline, MI
Supplier SIM Code: GQE2A
Part / System Name: Front Door Trim RH/LH Assembly
Key: From DFMEA:

YC
--
YS
Special Characteristic Totals: YC

Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SCs may be less than count of YSs 2
Special Characteristics Communication and Agreement for all U

Special Characteristics Communication and Agreement for all U
Stage 1. DFMEA
No.
Characteristic Description
1 Material Type/Flammability
Impact Bolster presence / poke yoke with adjacent compo
Color and Grain mismatch
3
Gloss level
Surface scratches / cuts / tears from material handling / ne
5
Parting Line Height (High visibility and touch zones areas)
Sink Marks
7
Loose Fasteners (screws, pal-nuts)
Foam seals Present on part
All Fasteners Present on part (push pins, screws, clips)
10
Heat Stakes / welds
11
Speaker Grille Burrs (speaker holes)
12
Armrest Softness
13
14 Armrest Trampoline Stitch location to Frame
15 Armrest Trampoline Fabric to stitch Edge

SC1 Top Roll (up/down height - Z)
16 RH: Specific coordinates to be provided
LH: Specific coordinates to be provided
SC2: Length of part (Fore-aft - X)

SC3: Door Trim to I/P Gap (Cross Car - Y)

18
RH: Specific coordinates to be provided


SC7: I/P footprint parallelism of points: SC3, SC4, SC
Cover-stock (knit backing or foam) to substrate Bond stren

Roll, armrest, Insert)
ISO 2411/ FLTM BN 151-05
WSS-M15P45-B 3.4.1
20
Ambient Lighting, FLOD and NLI continuity testing
21
Decorative stitch spacing to join seam
Functional Seam Alignment on part

Decorative Stitch - Stitch density
Overall leather Appearance quality

Natural markings book - to be checked by Eagle Ottawa
Part Boundary book - wrapping issues (wrinkles, fold types
22 Fit & finish
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Special C
1A. PFMEA & Special
Type ONLY in
ype ONLY in Yellow Boxes Characteristics Green Boxes
Agreement
Supplier Supplier/ Ford PD
JL7B-7823942-**W
Part Number:
JL7B-7823943-**W
Engineering Release Number: CPA Milestone
Design Lead Brand: Lincoln Navigator
Ford Customer Plant: Kentucky Truck Plant
From PFMEA:
Sev 9,10. Potential CC. CC Sev 9,10 (Part). Critical Characteristic.
SC
Sev 5-8. Potential SC. OS Sev 9,10 (Process). Operator Safety.
HI
Not Applicable Not applicable
YS CC
27 2
d Agreement for all UN content required to support UN design and development is

d Agreement for all UP content is required by UPV2.
cription Specification & Tole
Correct Material used per Ford Material

drawing.
(FMVSS 302 fully compliance)

MUST CONFORM TO: GENERAL REQU
FLAMMABILITY OF INTERIOR MATERI
h adjacent components Pelvic Bolster must be present on part a
Components must be equivalent as AAR
NOTE: The color of approved AAR boun

color master plaque and becomes target
component to achieve overall harmony.
Gloss level to approved AAR boundary s
NOTE: Gloss level of approved AAR bou

supersedes gloss callout on drawing or o
becomes target gloss value for each com
overall harmony.
terial handling / nesting
Door Trim must not have surface scratch

be as good as AAR boundary sample.
uch zones areas).
Parting line misalignment /flash is to mee

of 60 Microns (0.06mm) boundary samp
NOTE: Parts to be evaluated at AAR app

boundary plaque.
Evaluate surface imperfections as a resu

must be as good as AAR boundary samp
Correct Torque Spec as called out on dra
fully seated (no relative movement betwe
All foam seals present on part as release
s, screws, clips)
All fasteners present on part as released

Ensure all heat stakes are fully staked an
relative movement).
No Burrs in speaker grill holes beyond A

Must fall within DNA target range for Arm
(on Armrest softness curve - see worksh
Foam bun IFD and density per drawing
+/- 1.0mm to nominal stitch location
(stitch must be 2.0mm min. from edge of

ame
window)
+/- 1.0mm to nominal stitch location
e (stitch must be 2.0mm min. from edge of

ded +/- 1.0 (to be confirmed by tolerance
ded
0.0 ± 1.5 mm (to be confirmed by to
ded
ded
0.0 ±1.5 mm - * refer to fit and finish

ar - Y) confirmation of any of the following g
ded specs (to be confirmed by tolerance
ded
0.0 ±1.5 mm (to be confirmed by tol
ar - Y)
ded
ded

ar - Y)
ded
ded

ar - Y)
ded
ded
Largest delta between any SCs cann
s: SC3, SC4, SC5
equal to 2.0mm (to be confirmed by
bstrate Bond strength (Top
240 N/m min peel adhesion

Top Roll: 100% foam tear
ity testing Verify ambient lighting: FLOD, NLI and M
For wire harnesses:

1.) All screws and clips present,
2.) All clips fastened to map pocket/Pane
3.) Visual/sensing light presence check a
4.) Verify connectors intact with no dam
3.0 +/- 0.5 mm profile tolerance
+/- 1.0 profile tolerance

7 stitches per each inch (Tex 90)
+/- 1 stitch
by Eagle Ottawa See boundary book

wrinkles, fold types, etc.)
Reference fit & finish deck
Latest revision of Teamcenter file JL7
for Required Sections and Tolerance
Special Characteristics Communication and Agreem
2018 U554 Front Door

trim End Item Assembly
Special Charac
Signature
Ford D & R Engineer
Approval/Date:
Ford STA Engineer Signature
Approval/Date:
Ford Craftsmanship/Sys Engr'g Signature
Approval/Date:
Supplier Plant Quality Manager Signature
Approval/Date:
Note: approvals may be electronic
ahead of the name typed into the
as an attachment.
Sev 5-8 AND (Occ 4-10 or Ford D&R approval).

SC Significant Characteristic.
Sev 5-8 AND Occ 4-10. High Impact

HI Characteristic.
Not applicable
OS SC HI
0 11 0
d development is required by UNV2. The remaining UN content not required to su

DFMEA PFMEA
cation & Tolerance
Class Class
YC
Ford Material Specification on released
CC
nce)
ENERAL REQUIREMENTS FOR
RIOR MATERIAL REG20 SDS
sent on part and located correctly
YC CC
valent as AAR boundary sample. YS
ved AAR boundary sample supersedes

ecomes target color value for each
rall harmony.
Other
AR boundary sample +/- 0.5 YS
oved AAR boundary sample

n drawing or other documents and
e for each component to achieve Other
YS
urface scratches, cuts, or tears; must

ary sample.
Other
YS
flash is to meet visual attribute check

oundary sample
Other
ed at AAR approval against Ford
tions as a result of tooling / assembly; YS

boundary sample.
Other
YS
alled out on drawing & all fasteners are

ovement between components) Other
YS
part as released on drawing. Other
YS
art as released on drawing Other

YS
fully staked and fully seated (no

Other
oles beyond AAR boundary sample. YS
Other
range for Armrest Softness
e - see worksheet)
per drawing YS SC
h location
. from edge of trampoline frame

YS Other
h location
. from edge of trampoline fabric) YS Other

by tolerance analysis) YS SC
nfirmed by tolerance analysis)
YS SC
fit and finish deck ( supplied) for

e following gap and flushness YS SC
by tolerance analysis)
YS SC
YS SC
YS SC
ny SCs cannot be greater than or
confirmed by tolerance analysis) YS SC
sion
ar YS Other
OD, NLI and Map pocket YS
esent,
p pocket/Panel Other
sence check at all lighted locations
ct with no damage.
ance
YS SC
YS SC
ex 90)
YS SC
YS Other
ck
center file JL7B-FP-FDT YS Other
nd Tolerances
nd Agreement
Special Characteristics for:
ront Door JL7B-7823942

Faurecia, Saline, MI
Assembly JL7B-7823943
Special Characteristics Approvals required at UNV2 / UPV2 / PA as per FAP 03-111
Name e-mail
Raju Vemulapati svemula2@ford.com
Name e-mail
Katia Burlingame kburlin1@ford.com
Name e-mail
Fayaz Alamat falamat@ford.com
Name e-mail
Jeff Colliau jeffrey.colliau@faurecia.com
ay be electronic: complete the approval block above to identify the approvers,

typed into the "signature" box to indicate electronic approval and approve in e
t required to support UN design and development is required by <PA>.

Stage 1A. PFMEA
Process Control Method
Monitor/ verify conformance to specification:

- Capability: Not required
- Frequency: Material resupply in silo & Material change over a
- Sample Size: 100%
- Measurement System: Visual material certification when loadin
machine. Visual inspection of material change over at press.
Reaction Plan:
1) Operator to notify supervisor immediately
2) Supervisor / Gap Leader to contain and to check last part for
3) If no defects are found, inspector to verify previous workstatio
4) If defects are found, supervisor / Gap Leader to contain and t
in consecutive racks of parts.
5) Setup/inspector to verify previous workstation methods and/o
Material certification at PPAP and yearly recertification to verify m
to keep all test results/certifications on file and resubmit results/c
Material certification at PPAP and yearly recertification to verify m

to keep all test results/certifications on file and resubmit results/c
- Capability: Not required (show evidence that inspection is taking place
- Sample Size: 100% at launch/ 100% Long Term
- Measurement System: VP build: Visual/Hand mark.
TT, PP, MP 1&2, production: Part presence sensor. Traceability of b
- Reaction Plan: Follow corrective action sequence.

- Capability: Not required
- Frequency: Follow first piece approval process or color change
- Sample Size: Once at Post Grain (AAR) Customer approval pr
AAR boundary sample.
- Measurement System: Grain - Visual inspection per Master sa
either against master plaque provided by Ford or Southview-AA
to AAR). Mechanical evaluation using spectrophotometer.
- Capability: Not required (show evidence that inspection is takin
- Frequency: Follow first piece approval process or color change
- Measurement System: Gloss meter. Gloss Measurement in c
- Reaction Plan: Follow corrective action sequence. .

- Sample Size: Follow first piece approval process.
- Measurement System: Visual inspection
- Frequency (pre-production): 100% visual
- Frequency (on-going production): 100% visual with boundary s
sample.
Evidence of capability not required. Evidence of inspection is req
Sample Size: First piece inspection process, boundary sample
Measurement System: First piece visual Inspection to boundary
appearance master (verified to AAR).
Reaction plan: Faurecia and Ford to agree on an appropriate pr
integrity over time. If the parting line is approaching the maximu
maintenance plan schedule, Faurecia to immediately notify STA
issue an Alert. If repair is beyond normal tool maintenance, initia
(PCPF 046 Refurbishment) for PCA.

sample.
- Measurement System: Visual inspection per Master sample. N
Measurement system: Screws / Palnuts - Measure Torque as ca
control with angle monitoring. All driven fasteners must meet to
- PLC controlled to achieve correct setting. Annual calibration v
- Frequency: 100% DC driver application

TT, PP, MP 1&2, production: 100% Part presence sensor for

TT, PP, MP 1&2, production: Part presence sensors for all ap
- Sample Size: 100% at launch/ 100% Long Term (Visual and M
- Measurement System:
VP build: If heat stakes are hand welded then each heat stake m
TT, PP, MP1, MP2: Randomly select and perform heat stake pu
stake condition on the door. Locations must be reviewed and co
(but not limited to) differing material combinations, heat stake an
from 4-way locator (if resulting stake is other than 90 degrees) a
importance for fit or function as agreed to by Ford and Faurecia.
stake configuration with minimum pull strength value of 250N. (S
configurations and quantities.)
On-going production: Monitor and verify Parameter Settings (ele
energy, frequency, horn travel distance, horn alignment to stake
Visual inspection to boundary sample and confirm no relative mo
surfaces.
Annual pull strength test: Total sample size must be 6 minimum
with minimum pull strength value of 250N.
- Reaction Plan: Follow corrective action sequence. Reference

sample.
- Measurement System: Visual inspection per Master sample.
Control Point: Faurecia & Foam Supplier
Measurement system:
Assembly: Force/Displacement Curve on Instron machine wi
Foam bun only: IFD using Instron machine with 100N load ce
Frequency (pre-production- VP, TCB, TT, PP, MP1, MP2):

- Capability: N/A
- Sample Size: 100% at launch/ 1 x start of shift Long Term
- Measurement System: go/ no go gage
- Reaction plan: Follow corrective action sequence.

- Capability: N/A
- Measurement System: go/ no go gage
- Capability: PPk >1.67 at launch/ PPk>1.33 Long Term
- Sample Size: 100% at launch/ 1 X Shift per control plan.
- Measurement System: SPC Port(s) on Gage
Reference MSOW Section 2.3.C7





- Capability: Not required (show evidence that inspection is taking place
- Sample Size:
VP: Supplier must fill out adhesive checklist for VP process to be appro
adhesive checklist (see "Adhesive checklist" and "Adhesive Part Tags"
on Tensile Test machine.
Long Term: 1 pc per cavity per tool change to verify foam tear and Instr
After review of 30 days of data, frequency to be revised according to da
- Measurement System: Manual Peel Test - cohesive foam tear (Ford to
- Reaction plan: 1. Pull Alert, 2. Get D&R Manager & VO approval, 3. R
Faurecia shall check that the light comes on.
- Capability: N/A
Faurecia is responsible for damage to wire during assembly pro

- Capability: N/A
- Measurement System: Template with go/ no go lines

- Capability: N/A
- Measurement System: Template with go/ no go lines
- Capability: N/A
- Sample Size: 100% at launch/ 1 x shift Long Term
- Measurement System: Scale to check stitches per inch

sample.
- Measurement System: Visual inspection per Master sample.
Fit & Finish Checks
- Measurement System: Feeler guage
- Frequency; VP: Fit and Finish checks on 6 sets on fixture
TCB1: 1 pc, Fit & Finish all points
TT through MP1: 6 pcs, Fit & Finish all points
Production (post 90 days OK to Buy): 1st piece per shift, points red
Capability: Not required
Reaction Plan: If a non-conformance is identified, Faurecia will notify F
and severity of the issue. If necessary, an Alert will be pulled and appro
Quantity and frequency to be evaluated 30-60 days post PPAP.

JL7B-7823942-**W
JL7B-7823943-**W
/ PA as per FAP 03-111
Date
om 2/2/16
Date
m
Date
2/2/16
Date
recia.com
entify the approvers, and include "/s/"

oval and approve in e-mail with this file
d by <PA>.
Stage 1A. PFMEA
erial change over at press
ication when loading material into silo for overhead delivery to

e over at press.
check last part for boundary/master part acceptance.

previous workstation methods.
der to contain and to sort all parts for issue until zero defects are found
ion methods and/or manufacturing parameters

rtification to verify material meets FMVSS 302 requirements. Faurecia
d resubmit results/certifications at Ford request.
rtification to verify material meets FMVSS 302 requirements. Faurecia

d resubmit results/certifications at Ford request.
pection is taking place).
rk.
nsor. Traceability of bolster via serial number
e.
ess or color change.

stomer approval process. Color and grain match to be as good as the
ction per Master sample, Color - Visually check part in Macbeth booth
d or Southview-AAR equivalent approved appearance master (verified
ophotometer.
uence.
t inspection is taking place).
ess or color change.
stomer approval process. Follow first piece approval process.
Measurement in comparison to gloss specifications.
uence. .

ocess.
ual with boundary samples, must be as good as AAR boundary
uence.
of inspection is required.
boundary sample checks, and last piece inspection process.
pection to boundary plaque or Saline-AAR equivalent approved
n an appropriate preventive maintenance plan to maintain parting line

aching the maximum Boundary (plaque or AAR) prior to the
ediately notify STA. Faurecia and Ford to jointly initiate an ICA, and
maintenance, initiate a tooling refurbishment request to purchasing

r Master sample. No sink in excess of the Master sample.
uence.
asure Torque as called out on drawing w/ DC driver. Screws - torque
eners must meet torque tolerance requirements. Torque is set in driver
nnual calibration verification of torque on all drivers.
Term
uence.

Term
nd mark.
resence sensor for all foam pieces.
uence.

Term
nd mark.
ce sensors for all applicable fasteners.
quence.
Term (Visual and Manufacturing Parameters)
n each heat stake must be visually inspected and hand marked.

form heat stake pull strength test which represents each unique heat
be reviewed and concurred by Ford D&R engineers. Variables include
ions, heat stake angle (other than 90 degrees by design), distance
than 90 degrees) and any stake deemed to be of significant
Ford and Faurecia. Total sample size must be 20 minimum for each
h value of 250N. (See heat stake quality tab for guidance on
meter Settings (electrical continuity, temperature, time, air pressure,

alignment to stake boss, nesting and clamping to support joint area).
nfirm no relative movement between heat stake mushroom and mating
ust be 6 minimum (randomly selected) for each stake configuration
uence. Reference Non-Conforming Material, AEI-MOS-PR-12-E.

r Master sample.
uence.
Instron machine with 100N load cell.
e with 100N load cell and density
MP1, MP2):
hift Long Term
uence.
hift Long Term
uence.
Term
ol plan.
e.
Term
ol plan.
e.
Term
ol plan.
e.
Term
ol plan.
e.
Term
ol plan.
e.
Term
ol plan.
e.
Term
ol plan.
e.
pection is taking place).
P process to be approved by Ford and DV parts must be tagged with complete

Adhesive Part Tags" tabs)Pre-production; 6 pcs beginning run pre-production
y foam tear and Instron test required for 1pc per part per day for 30 days.
vised according to data.
ive foam tear (Ford to provide location) and Tensile test machine tear strength
& VO approval, 3. Rework/sort parts as required
Term
uring assembly process.
hift Long Term

go lines
uence.
hift Long Term

go lines
uence.
g Term
es per inch
uence.

r Master sample.
uence.
on fixture
e per shift, points reduced to critical areas (maximum 5 points)
Faurecia will notify Ford STA/PVT and review the data to establish the scope
be pulled and approved to allow shipment until issue is resolved.
s post PPAP.
nto silo for overhead delivery to
master part acceptance.

prueba de laboratorio
rts for issue until zero defects are found
uring parameters
ets FMVSS 302 requirements. Faurecia
s at Ford request.
ets FMVSS 302 requirements. Faurecia

s at Ford request.
revision de pines y mues
(Inspeccion visual)
rial number
Comparacion visual de pie

r and grain match to be as good as the
producidas contra master
- Visually check part in Macbeth booth
cliente
t approved appearance master (verified
ow first piece approval process.
o gloss specifications.
cliente

ust be as good as AAR boundary
cliente
d last piece inspection process.
Saline-AAR equivalent approved
laboratorio o usar planti
aintenance plan to maintain parting line
y (plaque or AAR) prior to the
especial
and Ford to jointly initiate an ICA, and
refurbishment request to purchasing
ust be as good as AAR boundary visual vs master de client

zonas (pigtogramas)
cess of the Master sample.
drawing w/ DC driver. Screws - torque
ce requirements. Torque is set in driver emsamble con pokayok
f torque on all drivers. (Torquimetro)
verificar peso vs especifica

eces.
Inspeccion visual
steners.
g Parameters)
ally inspected and hand marked.

est which represents each unique heat
Ford D&R engineers. Variables include
han 90 degrees by design), distance
ke deemed to be of significant Inspeccion visual y check
ple size must be 20 minimum for each
ake quality tab for guidance on
de parametros de la maqu
nuity, temperature, time, air pressure,

ng and clamping to support joint area).
tween heat stake mushroom and mating
selected) for each stake configuration
ming Material, AEI-MOS-PR-12-E.
ust be as good as AAR boundary

No hay producción
Pruebas de piel y vinil v
d cell.
ity
master
Visual y plantilla
N/A
No hay producción
No hay producción
Por confirmar Caracteristi


and DV parts must be tagged with completed

duction; 6 pcs beginning run pre-production Check list de parametros
inyeccion
red for 1pc per part per day for 30 days.
ation) and Tensile test machine tear strength

arts as required
No existe prueba electri
para el funcionamiento d
lampara (Se propone uso
lampara manual para ceri
prueba de luz)
se controla con plantilla

escala en diferentes zon

ust be as good as AAR boundary Revisar vs master (bunda

book)
al areas (maximum 5 points)
Revisar con Ismael
and review the data to establish the scope
shipment until issue is resolved.
laboratorio
nes y muescas
No hay producción final
on visual)
Se evalua colo
Graba
imperfeccion
visual de piezas arrug
ntra master del No hay master Firmado picadu
nte Raya
estri
cicatri
visual de piezas Opaci
ntra master del No hay master Firmado ton
nte
visual de piezas inspeccion con

ntra master del No hay master Firmado piez
nte
usar plantilla Realizar prueba
ecial
er de cliente y NO se han establecido

togramas)
on pokayoke No hay piezas producidas
imetro)
s especificación No hay producción
on visual No hay producción

ual y check list No hay piezas producidas
de la maquina
roducción N/A
piel y vinil vs
ster
plantilla
/A
roducción
roducción
Caracteristica Prueba realizada

Caracteristica
Caracteristica
Se realizo prueba dentro de

Caracteristica especificación
Caracteristica
parametros de revisar con inyección

ccion
ueba electrica
namiento de la
ropone uso de no hay pieza final
al para cerificar
de luz)
on plantilla y
erentes zonas
on plantilla y
erentes zonas
on plantilla y
erentes zonas
aster (bundary
ok)
on Ismael
e evalua color vs master
Grabado
mperfecciones en piel
arrugas
picaduras
Rayas
estrias
cicatrises
Opacidad
tono
speccion con tacto en la

pieza

Sscaf

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1.

Lead / Support roles and

Program: 2018 U554 Front Door trim End Item Assembly

Supplier Name/Plant: Faurecia, Saline, MI

Supplier SIM Code: GQE2A

Part / System Name: Front Door Trim RH/LH Assembly

Key: From DFMEA:

Special Characteristic Totals: YC

Special Characteristics Communication and Agreement for all U

Color and Grain mismatch

Surface scratches / cuts / tears from material handling / ne

Foam seals Present on part

All Fasteners Present on part (push pins, screws, clips)

Speaker Grille Burrs (speaker holes)

14 Armrest Trampoline Stitch location to Frame

15 Armrest Trampoline Fabric to stitch Edge

SC2: Length of part (Fore-aft - X)

SC3: Door Trim to I/P Gap (Cross Car - Y)

SC5: Door Trim to I/P Gap (Cross Car - Y)

SC6: Door Trim to I/P Gap (Cross Car - Y)

Cover-stock (knit backing or foam) to substrate Bond stren

Decorative stitch spacing to join seam

Functional Seam Alignment on part

Overall leather Appearance quality

Supplier Supplier/ Ford PD

Engineering Release Number: CPA Milestone

Design Lead Brand: Lincoln Navigator

Ford Customer Plant: Kentucky Truck Plant

d Agreement for all UN content required to support UN design and development is

Correct Material used per Ford Material

(FMVSS 302 fully compliance)

Components must be equivalent as AAR

NOTE: The color of approved AAR boun

NOTE: Gloss level of approved AAR bou

terial handling / nesting

Door Trim must not have surface scratch

Parting line misalignment /flash is to mee

NOTE: Parts to be evaluated at AAR app

Evaluate surface imperfections as a resu

All foam seals present on part as release

All fasteners present on part as released

No Burrs in speaker grill holes beyond A

Foam bun IFD and density per drawing

+/- 1.0mm to nominal stitch location

(stitch must be 2.0mm min. from edge of

+/- 1.0mm to nominal stitch location

e (stitch must be 2.0mm min. from edge of

0.0 ± 1.5 mm (to be confirmed by to

0.0 ±1.5 mm - * refer to fit and finish

0.0 ±1.5 mm (to be confirmed by tol

0.0 ±1.5 mm (to be confirmed by tol

bstrate Bond strength (Top

240 N/m min peel adhesion

For wire harnesses:

3.0 +/- 0.5 mm profile tolerance

+/- 1.0 profile tolerance

by Eagle Ottawa See boundary book

2018 U554 Front Door

Sev 5-8 AND (Occ 4-10 or Ford D&R approval).

Sev 5-8 AND Occ 4-10. High Impact

d development is required by UNV2. The remaining UN content not required to su

Ford Material Specification on released