Quality Ownership Engagement Program (Manual Checking Approach) Andon System Peer – to – Peer Product Confirmation

Sub Assy Main Assy Fitting Quality Ownership Engagement Program – Manual Checking Approach 1.0 OBJECTIVE Sub Assy Main Assy Fitting Objective Interface Concept Instill ‘right at the first time’ culture Enhance problem solving skill Enhance product & process quality ownership among workers Product confirmation Quick response to BIW requirement SOP – Self checking Product audit Peer –to- peer product confirmation Andon system

Quality Ownership Engagement Program – Manual Checking Approach BIW Area System Station External Appearance Fitting Part variation Andon Line stoppage for quality problem Fitting line Product Confirmation Main Assy line Internal Weld nut / hole missing / offset Part variation New self check methodology Confirm peer product before next process Peer – to – peer product confirm Sub Assy line

Final line & related groups Final line & related groups Quality Ownership Engagement Program – Manual Checking Approach 3.0 ANDON SYSTEM CONCEPT LINE ON LINE STOP LINE ON Pull Andon > Call related group > Discuss containment action > Decide repair – Online / offline > Investigate root cause > Plan for countermeasure Quality Problem? Repair affected body Insert at DL1B Interface Pull station stop string Preliminary report Problem solving report Certificate of repair Filling Final line & related groups Final line & related groups Final line Related groups QIT PIC

Quality Ownership Engagement Program – Manual Checking Approach 4.0 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT STAGE #1 STAGE #2 LAST STAGE Product Confirm Stage #1 Process Product Re-Confirm Stage #1 Product Confirm Stage #2 Process Process Product Re-Confirm # X Method Place marker to specified points Remove marker Place marker to next specified points Remove marker & put in the box Proposed Tools Magnet Marker Simple gauge Bolt / screw Hole plug

Quality Ownership Engagement Program – Manual Checking Approach 4.1 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT [CASE STUDY] 1 Fitting Line To confirm correct closure parts (RHS) installed to body Tool – magnet marker Date – Mar ‘12 [start] Rear door #5 (Closure) 5 2 Fitting #4 Fitting #9 3 4 Fitting #5 Fitting #8

Quality Ownership Engagement Program – Manual Checking Approach 5.0 IMPLEMENTATION PLAN NO SYSTEM STATION FOCUSED AREA 1 Andon Fitting Line Final Appearance Major repair Part variation 2 Peer – to – Peer Product Confirmation Sub Assembly Line Side Structure Front End Weld nut / hole missing / offset TF rejection

Quality Ownership Engagement Program – Manual Checking Approach 5.1 PEER – TO – PEER PRODUCT CONFIRMATION PROGRESS – FRONT END

Quality Ownership Engagement Program – Manual Checking Approach 5.2 PEER – TO – PEER PRODUCT CONFIRMATION PROGRESS – SIDE STRUCTURE S/Structure Line To confirm assist grip (front & rear ) nut not offset Tool – Hand gauge Date – July‘12 [start] 3 S/Struc Line #30 2 S/Struc Line #20 Check and Remove Gauge 1 Sub Assy #50 Install & Check Rear Side Nut Install & Check Front Side Nut

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