Utilize the Proactive QA Matrix Ranking: MODIFY THE "IDENTIFIED EQUIPMENT"

- Rank determines which Defects get attacked using JT Windshield Glass Cell BOX AND THE "QUALITY DEFECT" BOX
the X-Matrix and Quality Maintenance to FOR YOUR PROJECT
Proactively determine AM and PM activities on
components to maintain ZERO defects.

Equipment Caused Quality Defects:

Proactive QA Matrix identified equipment: - Incorrect Profile (no bead -
- Ergo Load Assist Unit wide/narrow bead -
- Prime / Prep Application Tooling intermittent/overlapped bead)
- Conveyor - Incorrect Bead Location
- Crowding Fixture - Glass out of Location for Bead
- Sealer Robots with Dispense Heads Application
- Sealer Dispense Systems - Insufficient "Suction" to Suction
- Coherix 3D Live Bead Audit Cups
- Purge Cart with Air Knife - Damaged Suction Cups
- MH Robot with End Effector - Incorrect Glass Location During
- Pull Off Fixture Decking
- Pass Fixture
- Decking Robots with INOS Vision
 2021 WL X-Matrix: Main Glass Cell Jeep

Inos Vision System

x
x Sealer Purge Cart Air Knife
x
x Sealer Purge Cart Waste Receptacle
x
x Flow Meter - Nordson Gear Metering Pump
(Motor Tach Ring with encoder) x
x x SpenTech Sealer Application Unit
Nozzles x x
x x Nordson Sealer Hoses
x
x Nordson Sealer Dispensing System
Temp Control Unit x
x Nordson Sealer Dispensing System
Barrels x
Conveyor S01CN1 / S01CN2 Glass Crowding
x x Fixture:
(Y Dir) Gear & Rack Mechanism
x x
Conveyor S01CN1 / S01CN2 Glass Crowding
x x Fixture:
(X Dir) Gear & Rack Mechanism
x x
Conveyor S01CN1 / S01CN2 Glass Crowding
x Fixture:
(Y Dir) Contact Rollers
x x
Conveyor S01CN1 / S01CN2 Glass Crowding
x Fixture:
(X Dir) Contact Rollers
x x
x x Fanuc MH Robot EOAT:
Vacuum Cups x
x Fanuc MH Robot EOAT:
Vacuum Generator x
x Fanuc MH Robot EOAT:
Vacuum Switch x
x x S01 Glass Load Ergo Load Assist Unit
Vacuum Cups x
x S01 Glass Load Ergo Load Assist Unit
Vacuum Generator x
x S01 Glass Load Ergo Load Assist Unit
Vacuum Switch x
Q Phenomena
Point Sketches

Abnormal Phenomena
Machine Components
Wear = 2mm or less (outside diameter)
nominal +/- 1mm to reference point

nominal +/- 1mm to reference point

Operating Degrees (F°) setup ± 5°

Location (X-Dir & Y-Dir) Details =

Location (X-Dir & Y-Dir) Details =

Cracks - Tears - Loose Hardware

In Place, Secure and Defect Free

Location Assist Details DO NOT

All Hoses & Hose Connections

(no bead - wide/narrow bead -

intermittent/overlapped bead)
Scratch Painted surfaces

Material Flow cc's ± 10%

Incorrect Glass Location

Incorrect Bead Location
Operating Air PSI ± 10%
Sealant Barrels in Place

Damaged Suction Cups

within acceptable range
INOS TCP Offset Limits

Not Full or Overflowing

Basic Condition (Wear)

Ideal Parameters
is not Bent / Damaged

Incorrect Bead Profile

Glass out of Location

Insufficient "Suction"
> Nozzle is in Place &

for Bead Application

Waste Receptacle is
& Contains Sealant
28 InHg +/- 5 InHg
Location (X Dir) =

Location (Y Dir) =
nominal +/- 2mm

to Suction Cups

During Decking
Defect Modes

x x x x x x x x x x x x Water Leaks
x x x
x x x x x x x x x x x x Squeaks / Whistles / Noise
x x x
x x x x x x x x x Visual Defect - Urethane Squeeze Out
x x x
x x x x x x Damaged / Broken Glass
x x x x
x x x x Visual Defect - Paint Scratched on Vehicle
x

PA Solutions, Inc. updated as of: August 22, 2019 D2AP / JNAP

 QM Matrix and 5 Questions for Zero Defect: WL Main Glass Cell

Nordson Sealer Dispensing

Nordson Sealer Dispensing

S01 Glass Load Ergo Load

S01 Glass Load Ergo Load

Conveyor S01CN1 / S01CN2

Conveyor S01CN1 / S01CN2

Sealer Purge Cart Waste

Sealer Purge Cart Air

Fanuc MH Robot EOAT:

Fanuc MH Robot EOAT:

Pump (Motor Tach Ring

Nordson Gear Metering
Glass Crowding Fixture:

Glass Crowding Fixture:

(X Dir) Contact Rollers

(Y Dir) Contact Rollers

Inos Vision System

Vacuum Generator

Vacuum Generator

Temp Control Unit

Vacuum Switch

Vacuum Switch

with encoder)
Conveyor S01CN1 / Conveyor S01CN1 /

Receptacle
Assist Unit

Assist Unit
S01 Glass Load Ergo Fanuc MH Robot S01CN2 Glass S01CN2 Glass SpenTech Sealer

System

System
Err:509

Err:509
Barrels

Knife
Machine Component > Load Assist Unit EOAT: Crowding Fixture: Crowding Fixture: Nordson Sealer Hoses Application Unit 0 0 0

0
Vacuum Cups Vacuum Cups (X Dir) Gear & Rack (Y Dir) Gear & Rack Nozzles
Mechanism Mechanism

Incorrect Bead Profile

(no bead - wide/narrow bead - X X X X X X X X
intermittent/overlapped bead)

Incorrect Bead Location X X X X X X X X X X

Glass out of Location
Condition
X X X X X X X X
for Bead Application
Insufficient "Suction"
X X X X X X
to Suction Cups

Damaged Suction Cups X X X X

Incorrect Glass Location
X X
During Decking
This section is filled by the
0
X-Matrix information

Operating Degrees (F°) setup ± 5°

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

Cracks - Tears - Loose Hardware

In Place, Secure and Defect Free
(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

(verify this is a value from HMI)

All Hoses & Hose Connections

Location (X-Dir & Y-Dir) Details =

nominal +/- 1mm to reference

nominal +/- 1mm to reference

Location Assist Details DO NOT

Material Flow cc's ± 10%

Operating Air PSI ± 10%

Sealant Barrels in Place
within acceptable range

within acceptable range

INOS TCP Offset Limits

INOS TCP Offset Limits

Not Full or Overflowing

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Basic Condition (Wear)

Scratch Painted surfaces
is not Bent / Damaged

(add prescribed cc's)

Waste Receptacle is
Wear = 2mm or less

Wear = 2mm or less

Nozzle is in Place &

& Contains Sealant
(outside diameter)

(outside diameter)
28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

28 InHg +/- 5 InHg

Location (X Dir) =

Location (Y Dir) =

(add temp)
point

point
Parameter (what to measure) > Part Data

Configur
e

Visual

Measure

Within - 2.0 - 2.0 Within

Specification Range / Limit > ± 5.0 ± 5.0 ± 5.0 ± 5.0 ± 5.0 ± 5.0 INOS + 0.0 + 0.0 ± 1.0 ± 1.0 ± 5° ± 10% INOS ± 10% ± 5.0 ± 5.0 ± 5.0 Gage

Method (how to measure) > Gage Gage Gage Visual Gage Gage Visual Gage Gage Measure Measure Measure Visual Measure Visual Visual Gage Visual Visual Visual Visual Gage Gage Visual Gage Gage Gage Visual Gage Visual Visual

Frequency of Check > weekly weekly daily weekly monthly monthly daily weekly monthly monthly monthly bi-weekly bi-weekly bi-weekly bi-weekly daily daily daily daily daily daily daily monthly daily daily daily daily daily daily daily daily

Responsible: AM Pillar / PM Pillar > PM PM AM PM PM PM PM PM PM PM PM PM PM PM PM AM AM AM/PM AM/PM PM PM AM PM PM AM PM PM AM AM AM AM AM

SMP - SOP number >

5 Questions for Zero Defects - Phase 0 (Before Improvements)

1-A fixed specification range is defined

1. Is the condition clear and

visible?
3-An easy to check method exists 3 3 5 3 3 3 5 3 3 5 5 3 5 3 5 5 5 5 5 5 5 5 3 5 5 3 3 5 3 5 5
5-Visual - easy to see at any time

1-Difficult to set, measure by hand

2. Is it easy to set? 3-Easy to adjust, fixed position 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 3 3 3 3 3 3 5 3 3 3 3 3 3 3 3 3

5-Preset, automatic set-up for each product type

1-During normal production in less than one shift

3. Is the value varying outside
the specification range? 3-Modified at each set-up/start-up 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 3 5 5 5 5 5 5 5 3 5 5 5 5 5 5 5
5-Varies only by exception
1-Low probability of seeing it
3-Inspection system has more than 90% probability of
4. Is the variation visible? finding 5 5 5 5 5 5 5 5 5 3 3 3 3 3 3 3 5 3 3 3 3 5 5 3 3 5 5 5 5 5 5
5-Continuous monitoring ensuring immediate alert

1-Difficult, requiring technical skills and downtime

5. Is it easy to restore? 3-Easy, once a person is qualified 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 3 3 3 3 3 3 3 3 3 3 3 3

5-Automatic adjustment (closed loop)
Phase 0 73% 76% 76% 84% 76% 76% 76% 84% 76% 76% 68% 68% 60% 68% 60% 68% 68% 84% 68% 68% 76% 76% 92% 76% 68% 76% 76% 76% 84% 76% 84% 84% 0%
5 Questions for Zero Defects - Phase 1 (After Improvements)
1-A fixed specification range is defined

1. Is the condition clear and

3-An easy to check method exists
visible?
5-Visual - easy to see at any time

1-Difficult to set, measure by hand

2. Is it easy to set? 3-Easy to adjust, fixed position

5-Preset, automatic set-up for each product type

1-During normal production in less than one shift

3. Is the value varying outside
3-Modified at each set-up/start-up
the specification range?
5-Varies only by exception

1-Low probability of seeing it

3-Inspection system has more than 90% probability of
4. Is the variation visible? finding

5-Continuous monitoring ensuring immediate alert

1-Difficult, requiring technical skills and downtime

5. Is it easy to restore? 3-Easy, once a person is qualified

5-Automatic adjustment (closed loop)

Phase 1 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
Error proofing N Y
Mistake-proofing
AM Calendar Activity (if yes, need SOP (CILR, where I = general
N Y
N Y
inspection)
OPL (plant-generated, differentiate good or bad) N Y
Work
PM procedure
Ledger (SMP/SOP)
Activity (if yes, needs SMP (change out/repair/technical
N Y
N Y
5 Questions for Zero Defects - Phase 2 (After Initial Production)
inspection)

1-A fixed specification range is defined

1. Is the condition clear and

3-An easy to check method exists
visible?
5-Visual - easy to see at any time

saved as: 841183859.xlsx page 3 of

 1-Difficult to set, measure by hand

2. Is it easy to set? 3-Easy to adjust, fixed position

5-Preset, automatic set-up for each product type

1-During normal production in less than one shift

3. Is the value varying outside
3-Modified at each set-up/start-up
the specification range?
5-Varies only by exception

1-Low probability of seeing it

3-Inspection system has more than 90% probability of
4. Is the variation visible? finding

5-Continuous monitoring ensuring immediate alert

1-Difficult, requiring technical skills and downtime

5. Is it easy to restore? 3-Easy, once a person is qualified

5-Automatic adjustment (closed loop)

Phase 2 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
Error proofing N Y
Mistake-proofing
AM Calendar Activity (if yes, need SOP (CILR, where I = general
N Y
N Y
inspection)
OPL (plant-generated, differentiate good or bad) N Y
Work
PM procedure
Ledger (SMP/SOP)
Activity (if yes, needs SMP (change out/repair/technical
N Y
N Y
inspection)

saved as: 841183859.xlsx page 4 of

 primarily part data and CMM measurement
data

measure and re-calibrate if needed

check the basic condition visually (is it there,
is it damaged, does it appear to be
functional)
requires a measurement tool

this is a physical gage - part of the system

PM AM/PM

5 Questions for Zero Defects After

Improvements
0.8

0.7

0.6

0.5

0.4

0.3

saved as: 841183859.xlsx 0.2 page 5 of

 0.2

0.1

0
Phase 0

saved as: 841183859.xlsx page 6 of