1. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:1 Error Proofing Error proofing is a structured approach to ensuring quality all the way through work process. Error-proofing can be applied for product/ part design and for process design (main application for production plant). Process FMEA (Failure Mode and Effect Analysis), is a methodology supporting error- proofing & it is used to define the potential risks of error. Note: In QMS error-proofing consists of 4 elements, but in MPS the focus is on error-proofing devices element only (the other 3 elements are covered completely by QMS).

2. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:2 Error Proofing Error-Proofing Device It is a physical device enhancing and/ or substituting human senses. It is used to sense, signal, or prevent potential error condition. It can be mechanical, electrical, pneumatic, or hydraulic devices. Examples for error-proofing devices: guide pins limit switches counters alarms checklists

3. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:3 Error Proofing Recommendations Awareness about error-proofing. Check the available error-proofing devices. Review processes to find the opportunities for establishing additional error-proofing methods (devices). Review by a team. Include error-proofing method the the quality planning and update the procedure (e.g. to be used for Stamping project).

4. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:4 Error Proofing Brake disc machining go/ no go gage used to prevent feeding the machine with the BD unless it is in the right position Examples of implementation at EGA

5. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:5 Error Proofing Body Shop Exact stud-welding positioning using guides Examples of implementation at EGA

6. EGA Egyptian German Auto. Co. A DaimlerChrysler joint venture in Egypt Mahmoud Ibrahim ElhefnawiQAADate:13.07.04Page:6 Error Proofing Ass. Line screw used to fix the car to the tilting machine Examples of implementation at EGA