POKA-YOKE

Conformity of Control Plan vs. W.I.

Control Plan vs. W.I. Presence Poka-Yoke

Product
No name Process POKA-YOKE etalon etalon on OK Start specific/ Dateline
no. New no. Control Plan W.I. Standard common
Test description OK KO
1.Conformity TD/TG No No No Specific
300 Mirror equipments Mirror equipments 2.Presence of "ocultor" No No No Specific
3.Presence of capsules No No No Specific
Pre-equipment Pre-equipment
400 (lamps assembly) (lamps assembly)
- - - - - -

Embossing and Body subassembly Embossing and Body subassembly

500 (screws & lamps assembly) (screws & lamps assembly)
- - - - - -
1 Megan
700 Glass assembly on body Glass assembly on body - - - - - -
740 Glue polymerization Glue polymerization - - - - - -
800 Photometry control Photometry control Presence of lamp position No No No Specific
1.Tightness conformity: inferior leakage Yes Common
900 Total tightness control Total tightness control to a diam hole. 0,5mm under 40 mbars Yes No
2. Presence of signalization lamp Yes Common
300A/B Mirror equipments Mirror equipments - - - - - -
400 Assembly of engine on housing - - - - - -
Assembly of cross component on
450 housing
- - - - - -
2 Polo A04
500 different classification of process Assembly of glass - - - - - -
900 Photometry and bonnets assembly - - - - - -
air pressure: 30mbars/3sec
950 Total tightness control
testing parameters: 22mbars/3sec
Yes No Yes Common
300 Mirror equipments Mirror equipments - - - - - -
500 Reflector assembly on body Reflector assembly on body - - - - - -
1. Conformity of part: Citroen / Peugeot
700 Glass loading on body Glass loading on body
2. Conformity of work station
No No No Specific
3 M49 740 Glue polymerization Glue polymerization - - - - - -
800 Photometry control Photometry control - - - - - -
air pressure in: 150mbars/3sec
900 Total tightness control Total tightness control air pressure out: 110mbars Yes No Yes Common
testing parameters: 40mbars/10sec
1.Conformity of TD/TG No No No Specific
2.Presence of the capsule No No No Specific
300 Mirror equipments Mirror equipments
3.Presence of the spring No No No Specific
4.Presence of the hinge No No No Specific
400 Clipping - body equipment Assembly of components 1. Conformity of clipping - no gap No No No Specific
4 Aixam 500 - Embossing - - - - - -
700 Line loading Mask location/lens Line loading Mask location/lens - - - - - -
740 Glue polymerization Photometry - - - - - -
800 Photometry control Projector assembly - - - - - -
1.Tightness conformity: inferior leakage
900 Total tightness control Total tightness control to a diam hole. 0,5mm under 40 mbars Yes No Yes Common
2.Conformity lighting turn signal lamp
The processes
100&200 are for 100 Platine assembly Platine assembly - - - - - -
Elliptic part
200 Reflector assembly Reflector assembly - - - - - -
The processes
300&400 are for Assembly on body: ocultor, lamps,
Halogen part 300 Assembly of Capsules
screws etc
- - - - - -

Tipo 400 Housing equipment Assembly on body: capsules - - - - - -

5 1.C-D Halogen Assembly on housing and
2.D Elliptic 500 Assembly on housing
Embossing
- - - - - -
Embossing and Assembly of the Assembly of the masque, lens +
700 masque, lens + gluing clipping
- - - - - -

800 Photometry control Photometry control - - - - - -

900 Total tightness control Total tightness control no technical specification Yes No Yes Common
1.Conformity of TD/TG No No No Specific
The Control Plan have specified
300 only the checking points: Assembly on housing 2.Presence of the capsule No No No Specific
1. conformity of parts
2.presence of components
3.Presence of the ocultor No No No Specific
300a 4.part deform, breakage, glue Change the reference - - - - - -
adhesion
6 S13 500 Poka-Yoke is requested at: Assembly of mask - - - - - -
a)conformity TD/TG Assembly of mask: differences for
500a b)presence of capsules&ocultor references
- - - - - -
c)gluing process- presence of
740 flame
Glue polymerization 1. Presence of flame No No No Specific
800 d)total tightness control Photometry control - - - - - -
e)labelling
900 Total tightness control no technical specification Yes No Yes Common

The Control Plan have specified 1.Conformity of TD/TG No No No Specific

300 assembly of lamp block
only the checking points: 2.Presence of the capsule No No No Specific
1. conformity of parts
400 2.presence of components reflector assembly - - - - - -
500 4.part deform, breakage, glue assembly of mask presence of lamp position No No No Specific
adhesion
7 Toledo Poka-Yoke is requested at: embossing reflector of intermittent
700 light
- - - - - -
a)conformity TD/TG
740 b)presence of capsules loading mask and clipping - - - - - -
c)presence of position lamp
800 d)photometry photometry and cover assembly no technical specification No No No Specific
e)total tightness control
900 Total tightness control no technical specification Yes No Yes Common

Page 1 Conformity of Control Plan vs. W.I.xls

 Control Plan vs. W.I. Presence Poka-Yoke
Product
No name Process POKA-YOKE etalon etalon on OK Start specific/ Dateline
no. New no. Control Plan W.I. Standard common
Test description OK KO
300 Assembly of the reflector Assembly of the reflector - - - - - -
400 Embossing of reflector Embossing of reflector - - - - - -
500 Housing equipment Housing equipment - - - - - -
Assembly of the glass, mask, Assembly of the glass, mask,
600 screws, lens screws, lens
Positioning and presence of filter No No No Specific
8 Zafira
740 Gluing Gluing - - - - - -
800 Photometry control Photometry control - - - - - -
850 Assembly of garniture Assembly of garniture - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common
100 Assembly of screen Assembly of screen Positioning and presence of screen No No No Specific

300 1.Detection TD / TG No No No Specific

Pre-equipment reflector BG/HG Pre-equipment reflector BG/HG
HG/BG 2.Positioning and presence of lens No No No Specific
Positioning and presence of the
400 Equipment reflector Equipment reflector
capsule
No No No Specific
9 Golf 500 Embossing Embossing - - - - - -
Assembly of the masque, lens + Assembly of the masque, lens +
700 gluing gluing
Positioning and presence of mask No No No Specific
800 Photometry control Photometry control - - - - - -
1.Positioning and presence of airvents No No No Specific
900 Total tightness control Total tightness control
2. no technical specification of test Yes No Yes Common
300 Equipment platine Equipment platine - - - - - -
Tappo/Fendi

400 Assembly of the elliptic Assembly of the elliptic - - - - - -

500 Embossing of the reflector Embossing of the reflector - - - - - -
10 Punto
Assembly of the masque, lens + Assembly of the masque, lens +
700 gluing gluing
Positioning and presence of mask No No No Specific
800 Photometry control Photometry control - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common
1.Detection TD / TG No No No Specific
300 Equipment reflector Equipment reflector
2.Positioning and presence of capsules No No No Specific
1.Positioning and presence of mask No No No Specific
400 Embossing Embossing
2.Positioning and presence of screen No No No Specific
11 Clio 500 Assembly of glass + gluing Assembly of glass + gluing - - - - - -
800 Photometry control Photometry control - - - - - -
850 Assembly of garniture Assembly of garniture - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common
950 Assembly of airvents and cover Assembly of airvents and cover conformity of Galia / product No No No Specific
1.Conformity of TD/TG No No No Specific
300 - Mirror equipments
2.Presence of capsules No No No Specific
400 Embossing Embossing 1.Presence of corrector electric No No No Specific
Line loading Mask location/lens Line loading Mask location/lens
800 Loading lens Loading lens
- - - - - -
Photometry and glue
12 T1 900 Photometry control
polymerization
Presence of position lamp - - - - -
1.Tightness conformity: inferior leakage
1100 Total tightness control Total tightness control to a diam hole. 0,5mm under 40 mbars Yes No Yes Common
2. Presence of signalization lamp
1. Label conformity with Galia and
product
1200 Packaging Cover (bonnet) assembly
2.Concordance Galia/product (product
No No No Specific
data introduction)
300 Equipment reflector Equipment reflector - - - - - -
Assembly of reflector and mask on Assembly of reflector and mask on
400 housing housing
- - - - - -
Glass checking, loading the Glass checking, loading the check the correct functioning during
500 entrance device entrance device glass assembly to the housing
No No No Specific
740 Glue polymerization Glue polymerization - - - - -
13 Corsa
800 Photometry control Photometry control - - - - -
air pressure in: 140mbars/3sec
900 Total tightness control Total tightness control air pressure out: 110mbars Yes No Yes Common
testing parameters: 30mbars/10sec
Mounting and checking of lamps
950 -
for CKD
- - - - - -

1.Detection TD / TG No No No Specific
300 Equipment reflector Equipment reflector
2.Positioning and presence of capsules No No No Specific
400 Embossing Embossing presence of reflector No No No Specific
Housing equipment - no
500 specification
Housing equipment + gluing - - - - - -
14 Vectra
700 Assembly of mask and glass Assembly of mask and glass presence of screen No No No Specific
740 Glue polymerization Glue polymerization - - - - - -
800 Photometry control Photometry control - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common -

Page 2 Conformity of Control Plan vs. W.I.xls

 Control Plan vs. W.I. Presence Poka-Yoke
Product
No name Process POKA-YOKE etalon etalon on OK Start specific/ Dateline
no. New no. Control Plan W.I. Standard common
Test description OK KO
1.Conformity of TD/TG No No No Specific
2.Presence of lamp4+spring No No No Specific
300BG Equipment reflector Equipment reflector
3.Presence of capsules No No No Specific
4.Presence of corrector electric No No No Specific
1.Presence of light shield H7+spring No No No Specific
300 Equipment reflector Equipment reflector 3.Presence of capsules No No No Specific
HG&Cupra
GP99 4.Presence of corrector electric No No No Specific
15 HG/BG
Cupra 400 Embossing Embossing - - - - - -
500 Body loading on plateau Body loading on plateau - - - - - -
700 Assembly of glass Assembly of glass - - - - - -
740 Glue polymerization Glue polymerization - - - - - -
800 Photometry control Photometry control - - - - - -
Tightness conformity: inferior leakage
900 Total tightness control Total tightness control
to a diam hole. 0,5mm under 40 mbars
Yes No Yes Common

250 Pre-equipment reflector Pre-equipment reflector - - - - - -

300 Equipment reflector Equipment reflector - - - - - -
500 Embossing Embossing - - - - - -
Assembly of the masque, lens +
16 Saxo 600 Assembly of the masque, lens + gluing
Positioning and presence of mask No No No Specific
700 gluing Clipping - - - - - -
800 Photometry control Photometry control - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common
1.Conformity of TD/TG No No No Specific
300 Equipment reflector Equipment reflector
2.Presence of the capsule No No No Specific
500 Embossing Embossing - - - - - -
Agila
Assembly of the masque, lens + Assembly of the masque, lens +
GM+Suzuki 700 gluing gluing
Positioning and presence of mask No No No Specific
17
Subcorsa 800 Photometry control Photometry control - - - - - -
GM+Suzuki
800CPL - Assembly of tape on garniture - - - - - -
850 Put join - - - - - - -
900 Total tightness control Total tightness control no technical specification No No Yes Common
250 Pre-equipment reflector Pre-equipment reflector Presence and normality of shutter No No No Specific
Presence of capsules
400 Equipment reflector Equipment reflector
Presence of corrector electric No No No Specific
Assembly of clips, reflector Assembly of clips, reflector
500 signaling and screen signaling and screen
Presence and Normality of clipping No No No Specific
18 Tigra
Loading the housing and the glass Loading the housing and the glass 1. Presence of screen
600 on the holder for robot process on the holder for robot process 2. Presence of mask
- - - - -

800 Photometry and strip assembly Photometry and strip assembly - - - - - -

900 Total tightness control Total tightness control no technical specification Yes No Yes Common
950 - Strip assembly - - - - - -
300 Pre-equipment reflector - - - - - -
CE / H4 The Control Plan have specified
350 only the checking points: Equipment reflector - - - - - -
1. conformity of parts
500 2.presence of components Assembly of glass and mask - - - - - -
19 C15 4.part deform, breakage, glue
740 Glue polymerization - - - - - -
adhesion
800 Poka-Yoke is requested at: Photometry control - - - - - -
a)total tightness control
900 Total tightness control no technical specification Yes No Yes Common
300 Pre-equipment reflector Pre-equipment reflector - - - - - -
H7 / LAD
1.Position and presence of black capsule
350 Equipment reflector Equipment reflector 2.Position and presence of white capsule No No No Specific
500 Embossing Embossing Assembly in 2 points No No No Specific
H7 / LAD
Assembly of the turn indicator Assembly of the turn indicator
20 Laguna 600 (signalization) (signalization)
Position and presence of signalization No No No Specific
X74-2
700 Assembly of mask, lens + gluing Assembly of mask, lens + gluing Presence of mask No No No Specific
800 Photometry control Photometry control - - - - - -
850 Assembly of support Assembly of support Position and presence of bulb holder No No No Specific
900 Total tightness control Total tightness control no technical specification Yes No Yes Common
H7 / LAD
300 Pre-equipment reflector Pre-equipment reflector - - - - - -
Assembly of glass, reflector + Assembly of glass, reflector +
700 gluing gluing
- - - - - -
21 GTF 740 Glue polymerization Photometry control - - - - - -
800 Photometry control - - - - - - -
900 Total tightness control Total tightness control no technical specification Yes No Yes Common

Legend:
processes different on Control Plan vs. W.I.
Poka-Yoke not Aplicable

Page 3 Conformity of Control Plan vs. W.I.xls

 Tests / Product Check rentability of investment

Megane M49 Aixam Tipo S13 Toledo Zafira Golf Punto Clio T1 Corsa Vectra GP99 Saxo Agila Tigra C15 Laguna GTF
HG HG BG Polo A04
VS+OES CKD VS+OES
H7 eliptic HG BG eliptic VS+OES HG BG CUPRA H7 LAD

Conformity TD / TG X X X X X X X X X X X X X X

Presence of "ocultor" X X X X X X X X

Witnesses projector X X X
Tightness -
hole diam 0.5mm under
X X X X X X X X X X X X X X X X X X X X X X X
40mbar
(<0.7l/m at 40mbar)
Conformity Lighting turn
X
signal lamp
Conformity of part
X
Citroen/Peugeot

Conformity of workstation X

Presence of capsules X X X X X X X X X X X X X X X

Presence of spring X

Presence of hinge X
Conformity of clipping - no
X
gap
Presence of flame X

Presence of reflector X
Presence and position
X X X
of position lamp
Photometry X
Positioning and presence
X
of filter
Positioning and presence
X X X
of screen
Positioning and presence
X
of lens
Positioning and presence
X X X X X X
of mask
Positioning and presence
X
of air vents

Conformity of Galia/product X X

1.Fixed and absence of

clearance
2.Absence of clearance at
the embossment
X
3.Presence of the
embossing tool liaison CE
in change / VD and absence
in CKD

correct functioning during

glass assembly to the X
housing

Presence of lamp4+spring X

Presence of corrector ball

X
socket
Presence of light shield
X
H7+spring
Presence and normality of
X
shutter
Presence and normality of
X
clipping
Assembly in 2 points X
Presence of signalization
X X X
lamp
Position and presence of
X X X
bulb holder

On "OK ?Demaraj" will be introducing: Punto: a) presence and fixation bulb-holder H1 & H7 b) conformity PN of Eliptic
 Assembly Process - number, name and description

Process
No.
Stage No. Process name Process description
Assembly line loading with necessa
100 Platine/reflector equipping
components
100-1 1 put reflector/platine on suport

2 assembly the capsule on reflector/paltines

3 activate the cycle
Capsule assembly and leveler
4 place the leveler on the platines
5 screw the leveler
6 release the platine

100-2 Elliptic assembly 1 place the equipped platines on suport

2 place the elliptic on platines/reflector
3 screw the eliptic on platines/reflector
100-3 Assembly of lamps and id reflector 1 place the ID reflector on the suport
2 place on the id reflector the equipped platines
3 screw the platines on the ID reflector
4 place the lamps
5 connect the harnesses

Reflector assembly with capsules,

200 Assembly of reflector
ocultor etc
200-1 Pre-assembly of reflector 1 Visual check of the reflector, place the reflector on the s
2 Screw the bulbholders
3 Place the lamps

200-2 Assembly of reflector 1 Place the reflector on the suport

2 Assembly the capsule
4 Activate the cycle of the machine

300 Embossing Assembly of reflector with mask

Assembly of the reflector on housing 1 Connect the harnesses of the city light
2 Connect the harnesses of the lamps
3 Place the ID reflector
4 Assembly the signaling lamp

Embossing on housing 2 Activate the cycle of the machine

Components assembly&Robot
400 Gluing process
Loading&Gluing
400-1 Assembly of mask and clipping on glace glace 1 place the first mask on the suport and clipp the seconda

2 Clipp the eliptic ring on mask

3 Place the glace on the suport
4 Clipp the equipped mask on the glace

400-2 Robot loading 1 Place the equipped housing on the suport

2 Place the equipped glace on the suport
3 Activate the cycle of the machine
 4 Polymerization

400-2-1 Glass checking, loading the entrance device

400-2-2 Glue channel heating
400-2-3 Assembly of lens on housing

500 Photometry control Check the disruption of headlamp

500-1 Photometry control 1 Place the headlamp on the suport
2 Connect the harnesses
3Activate the cylce of the machine

500-2 Assembly of cover 1 Place the headlamp on the suport

2 Assembly the covers

600 Tightness control Characteristics of process

600 Tightness control

700 Components removing Characteristics of process

1 Remove the lamps

2 Remove the leveler

3 remove the balast

4 Remove the signaling light

800 Super Control

1000 Packaging Palletisation

1000-1
 21-Apr-24
on
necessary

es

sules,

ctor on the suport

mask

bot

the secondary mask

dlamp