AU 536 P-FMEA Form Sheet Eng Variation 2

F M E A (F M E A) Nummer (Number): 1.1.
1
Prozess (Process) Seite (Page): 1/61
Typ/Modell/Fertigung/Charge (Type/Model/Fabrication/Lot): Arbeitsgangnummer (Item code): Verantwortlich (Responsible): Erstellt (Created): 13.07.2012
Prozeß FMEA KAB AU 536 Midfill Silicone Insert
Maßnahmenstand (Revision state): Firma (Company):
iSi Automotive GmbH
FMEA/Systemelement (FMEA/system element): Arbeitsgangnummer (Item code): Verantwortlich (Responsible): Erstellt (Created): 01.10.2013
Fertigung AU 536 KAB NAR/RdW 010, 200, 300-33x, 340-34x, 350, 610, 400, 500, Verändert (Modified): 03.07.2014
600, 800, 700, 810, 1000, 1900 + 2000, 060, Firma (Company):
070, 1250, 1100 iSi Automotive GmbH
Maßnahmenstand (Revision state):
Fehlerfolge (Effects) B K Fehlerart (Failure mode) K Fehlerursache (Cause) K Vermeidungsmaßnahme (Pre- A Entdeckungsmaßnahme (De- E RPZ V/T (R/D)
(S) (C) (C) (C) ventive action) (O) tection action) (D) (RPN)
Systemelement (System element): Laser Cutting
Funktion (Function): hang the foil in roll holder
foil is the mount from roll
holder dirty ( NOT RELE-
VANT )
Funktion (Function): hang the fabric roll in roll holder
[Prozeß KAB Midfill (Silicone 7 wrong fabric roll is mounted [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] in roll holder wrong fabric is used employee training plan 3 no process start possible 2 (42) Gottschalk, Markus, TX1;
committee Konstruktion, TE2;
QM, QM IAT / IAU Verantwortlich? (Responsi-
QM, QM IAT / IAU
BMG Freigabe ble?)
BMG Freigabe
(unbearbeitet (untouched)) Termin? (Deadline?)
unbearbeitet (untouched)
AA developing and implemen- (unbearbeitet (untouched))
ting in practice
QM, QM IAT / IAU
BMG Freigabe
(unbearbeitet (untouched))
design: various colors of diffe-
rent tissues
Konstruktion, TE2
BMG Freigabe
specifications : plausiblity
test is performed on the ma-
nufactured product and data
is scanned from the cloth
Gottschalk, Markus, TX1
BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 fabric roll is rotated by 180 ° S [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] in roll holder mounted (materi- orientation of the fabric roll employee qualifications: to 3 test: one set / cut- image 2 (42) Chonlatarn, Wachira, BL IAT;
committee al orientation) when mounting wrong make sure that exclusively + cut- template QM IAU / IAU, QM IAU / IAT;
and demonstrably trained per- QM, QM IAT / IAU
QM, QM IAT / IAU
sonnel this process step im- BMG Freigabe
plemented (quality matrix) control plan: periodic sensor
check
QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU
AA developing and implemen-
ting in practice
QM, QM IAT / IAU
specifications: gloss sensor
(position role in holder )
Chonlatarn, Wachira, BL IAT
[Prozeß KAB Midfill (Silicone 7 fabric roll is damaged during [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] suspension in roll holder not observed process acces- employee qualifications: to 3 visual inspection alter fa- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee sible handling make sure that exclusively bric roll mounting according QM, QM IAT / IAU
and demonstrably trained per- AA BMG Freigabe
sonnel this process step im- QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
plemented (quality matrix)
visual inspection at glu-
QM IAU / IAU, QM IAU / IAT eing according AA
AA developing and implemen- QM IAU / IAU, QM IAU / IAT
ting in practice
QM, QM IAT / IAU
fabric roll is the mount from
roll holder dirty (NOT RELE-
VANT)
Funktion (Function): pull sheet of film roll on Spreading Table
sheet removed too short
for the foil roll on spreading
table (NOT RELEVANT)
sheet during removal of
film roll on Table Spreading
dirty ( NOT RELEVANT )
Funktion (Function): cut sheet to defined length
sheet is cut to too great
length ( NOT RELEVANT )
[Prozeß KAB Midfill (Silicone 10 sheet is cut to length to [Technician] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] small (laser cutting residue sensor for length cutting of employee qualifications: to 2 visual inspection after cutting 3 (60) Chonlatarn, Wachira, BL IAT;
life too short (LAH.DUM.880. on fabric) the film web / web is set incor- make sure that exclusively according AA QM IAU / IAU, QM IAU / IAT;
BF) rectly and demonstrably trained per- QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 sonnel this process step im- BMG Freigabe
Insert)] plemented (quality matrix) control plan: periodic sensor
committee check
QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
sectional picture of the situati-
on in accordance with FA
length setting for sensor ac-
cording to table
Funktion (Function): --------------------------- BEGIN REPETITIVE STEPS ---------------------------
Funktion (Function): fabric panel of fabric roll on Spreading Table coordinated (20x)
web is too long removed
from fabric roll on Spreading
Table ( NOT RELEVANT ) (
20x)
[Prozeß KAB Midfill (Silicone 10 fabric panel damaged/ coa- S [Fabric Roll] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ting defects not met the standards speci- specific guidelines on TLV / 2 incoming goods inspection 4 (80) QM, QM IAA;
inflation too long ( LAH.DUM. fied drawing UPS with delivered parts QM, QM IAT / IAU
880.BF )
QM, QM IAA QM, QM IAT / IAU BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 unbearbeitet (untouched)
Insert)]
committee
[Prozeß KAB Midfill (Silicone 7 tissue web is pulled too short [Technician] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] of fabric roll on Spreading Ta- sensor for length cutting of employee qualifications: to 2 visual inspection after cutting 3 (42) Chonlatarn, Wachira, BL IAT;
committee ble ( 20x) the film web / web is set incor- make sure that exclusively according AA QM IAU / IAU, QM IAU / IAT;
rectly and demonstrably trained per- QM, QM IAT / IAU
check
QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
cording to table
web is wrong deducted
from fabric roll on Spreading
Table (NOT RELEVANT) (
20x)
[Prozeß KAB Midfill (Silicone 7 tissue web is pulled in too [Technician] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] small or too large number of number for the number of fa- employee qualifications: to 1 manual counting of the fabric 2 (14) QM IAU / IAU, QM IAU / IAT;
committee layers of fabric roll on Sprea- bric layers is set incorrectly make sure that exclusively layers according to AA QM, QM IAT / IAU
ding Table (<20x or >20x) and demonstrably trained per- QM IAU / IAU, QM IAU / IAT BMG Freigabe
sonnel this process step im- unbearbeitet (untouched)
ting in practice
QM, QM IAT / IAU
[Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
display the number of pieces employee qualifications: to 3 manual counting of the fabric 2 (42) QM IAU / IAU, QM IAU / IAT;
of fabric layers is not taken in- make sure that exclusively layers according to AA QM, QM IAT / IAU
to and demonstrably trained per- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
QM, QM IAT / IAU
web is the removal of tissue
on roller Spreading Table dir-
ty (NOT RELEVANT) ( 20x)
Funktion (Function): fabric panel is cut to the defined length (20x)
tissue web is cut up at gre-
at length (NOT RELEVANT)
( 20x)
[Prozeß KAB Midfill (Silicone 7 web is cut to length to be [Technician] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] small (20x) sensor for length cutting of employee qualifications: to 2 visual inspection after cutting 3 (42) Chonlatarn, Wachira, BL IAT;
committee the film web / web is set incor- make sure that exclusively according AA QM IAU / IAU, QM IAU / IAT;
rectly and demonstrably trained per- QM, QM IAT / IAU
check
QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
cording to table
Funktion (Function): --------------------------- END OF REPETITIVE STEPS ---------------------------
Funktion (Function): streak air pockets between fabric sheets

[Prozeß KAB Midfill (Silicone 7 air pockets between fabric [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] webs are not or insufficiently strikeouts not the entire sur- employee qualifications: to 3 visual inspection after cutting 3 (63) QM IAU / IAU, QM IAU / IAT;
committee spread face of the panels with a tool make sure that exclusively according AA QM, QM IAT / IAU
and demonstrably trained per- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
QM, QM IAT / IAU
fabric sheets are moved
on spreading the air pockets
against each other ( NOT RE-
LEVANT )
Funktion (Function): pull fabric stack of Spreading Table on conveyor
fabric stack is drawn
wrong ( NOT RELEVANT )
of Spreading Table on Con-
veyor
fabric sheets are moved
to conveyor in pulling the fa-
bric stack of spreading table
against each other (NOT RE-
LEVANT)
Funktion (Function): textile transport stack for laser cutter
( ERROR OPTIONS NOT
RELEVANT )
Funktion (Function): <S> Cut cut- out fabric image stack
[Prozeß KAB Midfill (Silicone 5 fabric stack is cut with the S [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] wrong cut-off image wrong item is selected employee qualifications: to 2 test with stencil after cut- 2 (20) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- make sure that exclusively ting with laser cutter accor- QM, QM IAT / IAU
me , no rework the product and demonstrably trained per- ding to AA and FA
necessary) BMG Freigabe
ting in practice
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 edges are burnt out fabric [Conveyor] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] stack when cutting the avera- dirty ocnveyor AA developing and implemen- 2 visual inspection before the la- 2 (28) QM IAU / IAU, QM IAU / IAT;
committee ge level of visibility ting in practice ser cuttingaccording AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
maintenance plan
TE2 Wien, TE2 Wien
[Laser Cutter] Maßnahmenstand - Anfang (Initial state): 21.08.2012
optic of the laser cutter dirty employee qualifications: to 2 visual inspection after cutting 3 (42) QM IAU / IAU, QM IAU / IAT;
make sure that exclusively according AA QM, QM IAT / IAU;
and demonstrably trained per- TE2 Wien, TE2 Wien
plemented (quality matrix) unbearbeitet (untouched)
ting in practice
QM, QM IAT / IAU
maintenance plan
TE2 Wien, TE2 Wien
decrease in power over life maintenance plan 2 visual inspection after cutting 3 (42) QM IAU / IAU, QM IAU / IAT;
too large according AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
QM IAU / IAU, QM IAU / IAT BMG Freigabe
defective components of the maintenance plan 3 visual inspection after cutting 3 (63) QM IAU / IAU, QM IAU / IAT;
laser cutter according AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
laser parameters of the laser employee qualifications: to 2 visual inspection after cut- 3 (42) Chonlatarn, Wachira, BL IAT;
cutter are set incorrectly make sure that exclusively ting according AA QM IAU / IAU, QM IAU / IAT;
ting in practice
QM, QM IAT / IAU
laser parameter list
[Prozeß KAB Midfill (Silicone 7 cut-off screen is not cut at all [Laser Cutter] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] tissue layers of fabric stack optic of the laser cutter dirty employee qualifications: to 2 visual inspection after cutting 3 (42) QM IAU / IAU, QM IAU / IAT;
committee make sure that exclusively according AA QM, QM IAT / IAU;
ting in practice
QM, QM IAT / IAU
maintenance plan
TE2 Wien, TE2 Wien
decrease in power over life maintenance plan 2 visual inspection after cutting 3 (42) QM IAU / IAU, QM IAU / IAT;
too large according AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
defective components of the maintenance plan 3 visual inspection after cutting 3 (63) QM IAU / IAU, QM IAU / IAT;
laser cutter according AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
laser parameters of the laser employee qualifications: to 2 visual inspection after cut- 3 (42) Chonlatarn, Wachira, BL IAT;
cutter are set incorrectly make sure that exclusively ting according AA QM IAU / IAU, QM IAU / IAT;
ting in practice
QM, QM IAT / IAU
laser parameter list
Funktion (Function): transport Sliced textile stapel from laser cutter
( ERROR OPTIONS NOT
RELEVANT )
Funktion (Function): take tissue blanks of conveyor , remove foil and place fabric sections on transportation cart
tissue blanks are not com-
plete removed from Con-
veyor (NOT RELEVANT)
[Prozeß KAB Midfill (Silicone 10 foil is not removed from fa- [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] bric stack not observed process acces-
life too short (LAH.DUM.880. sible handling
BF)
^ ^ ^ ^ ^ ^ ^ employee qualifications: to 3 visual inspection alter fa- 3 (90) QM IAU / IAU, QM IAU / IAT;
[...] 10 foil is not removed from fa- [Operator] make sure that exclusively bric roll mounting according QM, QM IAT / IAU
bric stack not observed process acces- and demonstrably trained per- AA BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 sible handling sonnel this process step im- QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
Insert)] plemented (quality matrix)
committee visual inspection at glu-
ting in practice
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 textile cuttings are contamina- [Conveyor] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] ted when removing conveyor dirty ocnveyor AA developing and implemen- 2 visual inspection before the la- 2 (40) QM IAU / IAU, QM IAU / IAT;
life too short (LAH.DUM.880. / remove the foil / drop on ting in practice ser cuttingaccording AA QM, QM IAT / IAU;
BF) Transport Cart TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 7 BMG Freigabe
Insert)] maintenance plan
committee TE2 Wien, TE2 Wien
[Transport Cart] Maßnahmenstand - Anfang (Initial state): 21.08.2012
dirty transport cart AA developing and implemen- 3 visual inspection before to ta- 2 (60) QM IAU / IAU, QM IAU / IAT;
ting in practice ke the fabric cuts on the trans- QM, QM IAT / IAU
QM, QM IAT / IAU port cart according AA BMG Freigabe
QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
ensure cleanliness require- employee qualifications: to 3 visual inspection at the begin- 3 (90) QM IAU / IAU, QM IAU / IAT;
ments in the process make sure that exclusively ning of the next sub process QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 textile cuttings are not [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] wrinkle- free stored on Trans- not observed process acces- employee qualifications: to 3 visual inspection alter fa- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee port Cart sible handling make sure that exclusively bric roll mounting according QM, QM IAT / IAU
and demonstrably trained per- AA BMG Freigabe
ting in practice
QM, QM IAT / IAU
Funktion (Function): see supreme fabric cutting and using stencil check (1x per production batch at the beginning )
[Prozeß KAB Midfill (Silicone 5 supreme fabric cutting is not [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] checked by Stencil (1x per not observed process acces- employee qualifications: to 3 visual inspection alter fa- 3 (45) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- production batch at the begin- sible handling make sure that exclusively bric roll mounting according QM, QM IAT / IAU
me , no rework the product ning) and demonstrably trained per- AA
necessary) BMG Freigabe
ting in practice
QM, QM IAT / IAU
supreme fabric section is
checked in error by Stencil
(1x per production batch at
the beginning) (NOT RELE-
VANT)
Funktion (Function): dispose of scrap in big bag
( ERROR OPTIONS NOT RE-
LEVANT )
Funktion (Function): transport textile blanks to glueing machine
( ERROR OPTIONS NOT
RELEVANT )
Funktion (Function): trouble-free process
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Fabric Roll] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] not met the standards speci- specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
process stop (only losing ti- fied drawing UPS with delivered parts QM, QM IAT / IAU
me , no rework the product
necessary) QM, QM IAA QM, QM IAT / IAU BMG Freigabe
[Prozeß KAB Midfill (Silicone 7
Insert)]
committee
Systemelement (System element): Glueing + Curing
Merkmal (Characteristic): <F> Identität Cushion
[Prozeß KAB Midfill (Silicone 10 identity Cushion faulty F [Glueing + Curing, Tracebility Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] system] specifications: adoption and 2 plausibility check of data 2 (40) Gottschalk, Markus, TX1;
life too short (LAH.DUM.880. records results of the pro- adaptation / adaptation of pro- Massinger, Jörgen Michael,
BF) cess lead to faulty Massinger, Jörgen Michael, IT
ven series HW and SW com- IT;
[Prozeß KAB Midfill (Silicone 6 ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
Insert)] results
Gottschalk, Markus, TX1 BMG Freigabe
identification is not possible QM, QM IAT / IAU unbearbeitet (untouched)
of the airbag and / or of com- PASS system after release
ponents of the validated algorithms sa-
fed against changes
Insert)] Massinger, Jörgen Michael, IT
identification of the airbag
and / or components only to
a limited extent
Insert)]
and / or components wrong
Insert)]
and / or components only
with increased effor
Insert)]
process stop with n.i.O. cha-
racterization (part blocked)
[Prozeß KAB Midfill (Silicone 6 no identity Cushion F [Glueing + Curing, Tracebility Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] system]
identification is not possible records results of the pro-
of the airbag and / or of com- cess cycle defective / not on
ponents
^ ^ ^ ^ ^F ^ ^ specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 6 no identity Cushion [Glueing + Curing, Tracebility adaptation / adaptation of pro- Massinger, Jörgen Michael,
Massinger, Jörgen Michael, IT
[...] system] ven series HW and SW com- IT;
records results of the pro- ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 cess cycle defective / not on results
Insert)] QM, QM IAT / IAU unbearbeitet (untouched)
process stop with n.i.O. cha- PASS system after release
racterization (part blocked) of the validated algorithms sa-
fed against changes
Funktion (Function): equip placement machine with Silicone Inserts
[Prozeß KAB Midfill (Silicone 5 placement machine is faulty [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] fitted with Silicone Inserts not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (45) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
me , no rework the product and demonstrably trained per- TE2 Wien, TE2 Wien
necessary) TE2 Wien, TE2 Wien
plemented (quality matrix) machine downtime in the
next part process
TE2 Wien, TE2 Wien
ting in practice control plan: visual inspecti-
on visual inspection on the
QM, QM IAT / IAU light table, each part 10
manual counting the cushi-
ons before placing them on
the board in accordance with
AA for storage rack
[Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 22.08.2012
rotary position and / or orien- employee qualifications: to 3 keine 10 (150) Konstruktion, TE2;
tation (side) of the silicone in- make sure that exclusively QM IAU / IAU, QM IAU / IAT;
serts are not observed in and demonstrably trained per- QM, QM IAT / IAU;
pick and place machine sonnel this process step im- TE2 Wien, TE2 Wien
plemented (quality matrix) BMG Freigabe
ting in practice
QM, QM IAT / IAU
constructive: consider tab for
the rotational orientation
Konstruktion, TE2
form-fitting on bearing sur-
face
TE2 Wien, TE2 Wien
Maßnahmenstand (Revision state): 24.04.2013
AA developing and implemen- 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
nance plan QM, QM IAT / IAU
QM, QM IAT / IAU
specifications: sensor
scanning with (rotary) the tab visaul inspection in further
on silicone insert process according AA
Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT
specifications: vacuum mo- control plan: periodic sensor
nitoring (orientation) of silico- test with test pieces
ne insert QM, QM IAT / IAU
Gottschalk, Markus, TX1 control plan: 100% inspec-
tion
[Prozeß KAB Midfill (Silicone 10 silicone inserts contaminati- [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] on during loading the assemb- ensure cleanliness require- employee qualifications: to 3 keine 10 (300) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- ly aid ments in the process make sure that exclusively QM, QM IAT / IAU
ring undefined ( LAH.DUM. and demonstrably trained per-
880.BF , use safety ) BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 plemented (quality matrix)
Insert)] QM IAU / IAU, QM IAU / IAT
seek time is too long (LAH.
DUM.880.BF) AA developing and implemen-
ting in practice
Insert)] QM, QM IAT / IAU
inflation too long ( LAH.DUM. Maßnahmenstand (Revision state): 22.08.2012
880.BF )
define residual contaminati- 2 keine 10 (200) Fiedler, Jens, TE2 IAB;
[Prozeß KAB Midfill (Silicone 10 on requirements for handling Gottschalk, Markus, TX1;
control plan: visual inspec-
Insert)] of silicone insert QM IAU / IAU, QM IAU / IAT;
tion in the process, if position
life too short (LAH.DUM.880. QM, QM IAT / IAU;
Fiedler, Jens, TE2 IAB criterien are met TE2 Wien, TE2 Wien
BF)
employee qualifications: to QM IAU / IAU, QM IAU / IAT BMG Freigabe
make sure that exclusively unbearbeitet (untouched)
Insert)]
and demonstrably trained per-
filling gas flows directly into
sonnel this process step im-
vehicle interior
ting in practice
QM, QM IAT / IAU
specifications: define work-
place equipment / design for
each process step
define maintenance plan
TE2 Wien, TE2 Wien
Funktion (Function): <S> insert and align first main panel in Glueing Machine
[Prozeß KAB Midfill (Silicone 7 first Main panel is misaligned S [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] after inserting in Glueing Ma- marks for Main Panels in Glu- employee qualifications: to 3 control plan: visual inspec- 2 (42) Gottschalk, Markus, TX1;
committee chine eing Machine are not obser- make sure that exclusively tion for contamination in the QM IAU / IAU, QM IAU / IAT;
ved and demonstrably trained per- process QM, QM IAT / IAU
sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
QM, QM IAT / IAU
specifications: positioning
helper for lower vacuum devi-
ce
specifications: coverage of
the lower to the upper blank
^[...] ^ ^S ^ Gottschalk, Markus, TX1 ^[...] ^[...] ^[...] ^[...] ^[...]
[Prozeß KAB Midfill (Silicone 10 first Main panel is dirty when S [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] engaging in Glueing Machi- ensure cleanliness require- employee qualifications: to 3 keine 10 (300) QM IAU / IAU, QM IAU / IAT;
life too short (LAH.DUM.880. ne ( see tissue defect cata- ments in the process make sure that exclusively QM, QM IAT / IAU
BF) log ) and demonstrably trained per- BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 sonnel this process step im- unbearbeitet (untouched)
inflation too long ( LAH.DUM. QM IAU / IAU, QM IAU / IAT
880.BF )
ting in practice
QM, QM IAT / IAU
on requirements for handling Gottschalk, Markus, TX1;
of silicone insert QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
Fiedler, Jens, TE2 IAB criterien are met
TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
each process step
TE2 Wien, TE2 Wien
Funktion (Function): <S> insert and align the second main panel in Glueing Machine
[Prozeß KAB Midfill (Silicone 7 second Main Panel is not ali- S [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] gned after insertion in Glu- marks for Main Panels in Glu- employee qualifications: to 3 control plan: visual inspec- 2 (42) Gottschalk, Markus, TX1;
committee eing Machine eing Machine are not obser- make sure that exclusively tion for contamination in the QM IAU / IAU, QM IAU / IAT;
ved and demonstrably trained per- process QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
helper for lower vacuum devi-
ce
specifications: coverage of
the lower to the upper blank
[Prozeß KAB Midfill (Silicone 10 second Main panel is dirty S [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] when engaging in Glueing ensure cleanliness require- employee qualifications: to 3 keine 10 (300) QM IAU / IAU, QM IAU / IAT;
life too short (LAH.DUM.880. Machine ments in the process make sure that exclusively QM, QM IAT / IAU
BF) and demonstrably trained per- BMG Freigabe
inflation too long ( LAH.DUM. QM IAU / IAU, QM IAU / IAT
880.BF )
ting in practice
QM, QM IAT / IAU
on requirements for handling Gottschalk, Markus, TX1;
of silicone insert QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
Fiedler, Jens, TE2 IAB criterien are met
TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
each process step
TE2 Wien, TE2 Wien
Funktion (Function): suction of the entire surface of Lower Main Panels Vacuum Device
( ERROR OPTIONS NOT
RELEVANT )
Funktion (Function): record second Main Panel by Upper Vacuum Device
[Prozeß KAB Midfill (Silicone 7 second Main Panel hangs [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] when recording through Up- Machine, Vacuum Device] maintenance plan 3 process monitoring by opera- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee per Vacuum Device partially vacuum device defective/ dir- tor according to AA TE2 Wien, TE2 Wien
shut ty TE2 Wien, TE2 Wien
Funktion (Function): <S> Silicone line apply on first Main Panel
[Prozeß KAB Midfill (Silicone 7 silicone line is incompletely S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] applied to 1st main panel Machine, Application System] maintenance plan 3 control plan: 100% visual in- 3 (90) QM IAU / IAU, QM IAU / IAT;
committee application System faulty / dir- spection on the light table, TE2 Wien, TE2 Wien
ty TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 each 10 th piece BMG Freigabe
Insert)] QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
Airbag inflates when trigge-
ring undefined ( LAH.DUM. [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
880.BF , use safety ) Machine, CNC Robot Arm] maintenance plan 3 control plan: visual inspecti- 3 (90) QM IAU / IAU, QM IAU / IAT;
defective CNC Robot Arm on visual inspection on the TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 TE2 Wien, TE2 Wien
Insert)] light table, each part 10 BMG Freigabe
seek time is too long (LAH. QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
DUM.880.BF)
review of the silicone line
width / thickness
[Prozeß KAB Midfill (Silicone 10 ^ ^S ^ ^
employee qualifications: to 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
Insert)] silicone line is incompletely [Glueing + Curing, Operator]
make sure that exclusively nation at the beginning of the QM, QM IAT / IAU
inflation too long ( LAH.DUM. applied to 1st main panel review of the silicone line
and demonstrably trained per- next part of periodic review BMG Freigabe
880.BF ) width / thickness
sonnel this process step im- process / process step Light unbearbeitet (untouched)
[Prozeß KAB Midfill (Silicone 10 plemented (quality matrix) Table
Insert)]
QM IAU / IAU, QM IAU / IAT QM IAU / IAU, QM IAU / IAT
life too short (LAH.DUM.880.
BF) AA developing and implemen- control plan 100% came-
ting in practice ra inspection (DSS )
Insert)] QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
vehicle interior
[Prozeß KAB Midfill (Silicone 7 silicone line is uneven or S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] even too thin / too thick to Machine, Application System] maintenance plan 3 control plan: 100% visual in- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee 1st main panel application System faulty / dir- spection on the light table, TE2 Wien, TE2 Wien
each 10 th piece BMG Freigabe
[Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Machine, CNC Robot Arm] maintenance plan 3 control plan: visual inspecti- 3 (63) QM IAU / IAU, QM IAU / IAT;
defective CNC Robot Arm on visual inspection on the TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
light table, each part 10 BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 silicone line is applied with S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] air pockets on 1st main panel Machine, Application System] maintenance plan 3 control plan: 100% visual in- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee application System faulty / dir- spection on the light table, TE2 Wien, TE2 Wien
each 10 th piece BMG Freigabe
[Prozeß KAB Midfill (Silicone 5 silicone line is plotted with [Technican] Maßnahmenstand - Anfang (Initial state): 28.02.2013
Insert)] wrong path trace to 1st main the wrong program at the plausiblity test of sensor on 2 machine acceptance report 2 (28) Massinger, Jörgen Michael,
process stop (only losing ti- panel right armor the armor module to the loa- results IT;
me , no rework the product ded program QM IAU / IAU, QM IAU / IAT;
necessary) QM, QM IAT / IAU
QM, QM IAT / IAU
Massinger, Jörgen Michael, IT BMG Freigabe
Insert)] BMG Freigabe (unbearbeitet (untouched))
committee (unbearbeitet (untouched)) periodic sensor check (error
training and AA provocation)
QM, QM IAT / IAU QM, QM IAT / IAU
BMG Freigabe BMG Freigabe
(unbearbeitet (untouched)) (unbearbeitet (untouched))
employee qualifications: to no process start possible
make sure that exclusively Verantwortlich? (Responsi-
and demonstrably trained per- ble?)
plemented (quality matrix) Termin? (Deadline?)
control plan: 100% visual
BMG Freigabe inspection on the light table,
(unbearbeitet (untouched)) each 10 th piece
BMG Freigabe
control plan 100% came-
ra inspection (DSS )
BMG Freigabe
Funktion (Function): <S> Silicone insert automatically populated with the help of the placement machine on the inflation opening of the first Main Panel
[Prozeß KAB Midfill (Silicone 7 silicone insert is not in the cor- S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] rect position placed on inflati- Machine, Handling System maintenance plan 2 control plan: visual inspecti- 2 (28) QM IAU / IAU, QM IAU / IAT;
committee on opening of the 1st main (Silicone Insert)] on visual inspection on the TE2 Wien, TE2 Wien
panel vacuum is not sufficient TE2 Wien, TE2 Wien
[Technican] Maßnahmenstand - Anfang (Initial state): 28.02.2013
the wrong program at the plausiblity test of sensor on 2 machine acceptance report 2 (28) Massinger, Jörgen Michael,
right armor the armor module to the loa- results IT;
ded program QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
QM, QM IAT / IAU
BMG Freigabe
BMG Freigabe (unbearbeitet (untouched))
(unbearbeitet (untouched)) periodic sensor check (error
make sure that exclusively Verantwortlich? (Responsi-
plemented (quality matrix) Termin? (Deadline?)
control plan: 100% visual
BMG Freigabe inspection on the light table,
(unbearbeitet (untouched)) each 10 th piece
BMG Freigabe
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 silicone insert is pressed on S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] the wrong height on inflation Machine, Handling System maintenance plan 2 control plan: visual inspecti- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- opening of the 1st main panel (Silicone Insert)] on visual inspection on the TE2 Wien, TE2 Wien
ring undefined ( LAH.DUM. vacuum is not sufficient TE2 Wien, TE2 Wien
880.BF , use safety )
Insert)]
DUM.880.BF)
Insert)]
inflation too long ( LAH.DUM.
880.BF )
Insert)]
BF)
[Prozeß KAB Midfill (Silicone 10 ^ ^S ^ ^ ^ ^ ^ ^ ^ ^
Insert)] silicone insert is pressed on [Glueing + Curing, Glueing TE2 Wien, TE2 Wien 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
filling gas flows directly into the wrong height on inflation Machine, Handling System unbearbeitet (untouched)
vehicle interior opening of the 1st main panel (Silicone Insert)]
[Prozeß KAB Midfill (Silicone 7 vacuum is not sufficient
Insert)]
committee
[Prozeß KAB Midfill (Silicone 10 silicone insert is raised again S [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] after pressing on inflation ope- Machine, Handling System maintenance plan 2 control plan: visual inspecti- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- ning of the 1st main panel or (Silicone Insert)] on visual inspection on the TE2 Wien, TE2 Wien
ring undefined ( LAH.DUM. moved vacuum is not sufficient TE2 Wien, TE2 Wien
Insert)]
DUM.880.BF)
Insert)]
880.BF )
Insert)]
BF)
Insert)]
vehicle interior
Insert)]
committee
Funktion (Function): <S> settle second Main Panel with Upper Vacuum Device on first Main Panel
[Prozeß KAB Midfill (Silicone 10 Cushion is raised to first [Glueing + Curing, Glueing Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] main panel after discontinuati- Machine, Vacuum Device] maintenance plan 3 process monitoring by opera- 3 (90) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- on of the second Main Panel vacuum device defective/ dir- tor according to AA TE2 Wien, TE2 Wien
ring undefined ( LAH.DUM. with Upper Vacuum Device ty TE2 Wien, TE2 Wien
880.BF , use safety ) QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)]
DUM.880.BF)
Insert)]
880.BF )
Insert)]
BF)
Insert)]
vehicle interior
Insert)]
committee
[Prozeß KAB Midfill (Silicone 10 line width / thickness of S [Technican] Maßnahmenstand - Anfang (Initial state): 28.02.2013
Insert)] the silicon line and track the wrong program at the plausiblity test of sensor on 2 machine acceptance report 2 (40) Massinger, Jörgen Michael,
Airbag inflates when trigge- when you issue the 2 main right armor the armor module to the loa- results IT;
ring undefined ( LAH.DUM. panels with upper vacuum de- ded program QM IAU / IAU, QM IAU / IAT;
880.BF , use safety ) vice to 1st main panel too wi- QM, QM IAT / IAU
QM, QM IAT / IAU
de Massinger, Jörgen Michael, IT BMG Freigabe
Insert)] BMG Freigabe (unbearbeitet (untouched))
seek time is too long (LAH. (unbearbeitet (untouched)) periodic sensor check (error
DUM.880.BF) training and AA provocation)
[Prozeß KAB Midfill (Silicone 10 QM, QM IAT / IAU QM, QM IAT / IAU
Insert)] BMG Freigabe BMG Freigabe
inflation too long ( LAH.DUM. (unbearbeitet (untouched)) (unbearbeitet (untouched))
880.BF )
[Prozeß KAB Midfill (Silicone 10 make sure that exclusively
Insert)] Verantwortlich? (Responsi-
life too short (LAH.DUM.880. sonnel this process step im-
BF) plemented (quality matrix) Termin? (Deadline?)
[Prozeß KAB Midfill (Silicone 10 (unbearbeitet (untouched))
Insert)] control plan: 100% visual
filling gas flows directly into BMG Freigabe inspection on the light table,
vehicle interior (unbearbeitet (untouched)) each 10 th piece
[Prozeß KAB Midfill (Silicone 7 QM IAU / IAU, QM IAU / IAT
Insert)] BMG Freigabe
committee (unbearbeitet (untouched))
BMG Freigabe
Funktion (Function): boot Upper Vacuum Device
( ERROR OPTIONS NOT
RELEVANT )
Funktion (Function): rate of cushion and confirmation by printing the label
[Prozeß KAB Midfill (Silicone 5 no confirmation from the la- [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 31.01.2013
Insert)] bel printing contour verification NOK employee qualifications: to 2 control plan: visual examinati- 2 (20) QM IAU / IAU, QM IAU / IAT;
unnecessary prolongation of make sure that exclusively on at the beginning of the QM, QM IAT / IAU
the cycle time / lead time and demonstrably trained per- next sub-process periodic re- BMG Freigabe
sonnel this process step im- view unbearbeitet (untouched)
plemented (quality matrix) QM IAU / IAU, QM IAU / IAT
QM IAU / IAU, QM IAU / IAT control plan 100% camera in-
AA developing and implemen- spection (DSS )
ting in practice QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU
Funktion (Function): <F> Apply Label Cushion on bottom of the first Main Panel
[Prozeß KAB Midfill (Silicone 7 Label Cushion is applied in- F [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] correctly to 1 Main Panel not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
[Prozeß KAB Midfill (Silicone 6 and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
Insert)] sonnel this process step im- BMG Freigabe
identification is not possible plemented (quality matrix) machine downtime in the
of the airbag and / or of com- next part process
ponents TE2 Wien, TE2 Wien
ting in practice
[Prozeß KAB Midfill (Silicone 7 ^ ^F ^ ^ [...] ^ control plan: visual inspecti- ^ ^ ^
Insert)] Label Cushion is applied in- [Glueing + Curing, Operator] 3 on visual inspection on the 3 (63) BMG Freigabe
process stop with n.i.O. cha- correctly to 1 Main Panel not observed process acces- QM, QM IAT / IAU light table, each part 10 unbearbeitet (untouched)
racterization (part blocked) sible handling
AA for storage rack
[Prozeß KAB Midfill (Silicone 6 Label Cushion is not applied [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 22.08.2012
Insert)] in the correct position on 1 page and / or position is not employee qualifications: to 3 control plan: visual examinati- 2 (36) QM IAU / IAU, QM IAU / IAT;
process stop (rework on pro- Main Panel observed on the main panel make sure that exclusively on at the beginning of the QM, QM IAT / IAU
duct possible / required) for label cushion and demonstrably trained per- next part of the process BMG Freigabe
ting in practice
QM, QM IAT / IAU
Funktion (Function): <(S)*> pull Cushion from Glueing Machine on Curing Board
[Prozeß KAB Midfill (Silicone 7 silicone line of the cushion is [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] damaged when pulling out not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee glueing machine on curing sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
board and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
AA for storage rack
[Prozeß KAB Midfill (Silicone 10 more than 10 Cushions are S [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] pulled from Glueing Machine not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
life too short (LAH.DUM.880. on Curing Board sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
BF) and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
Insert)] plemented (quality matrix) machine downtime in the
committee next part process
TE2 Wien, TE2 Wien
AA for storage rack
[Prozeß KAB Midfill (Silicone 7 silicone insert is moved from [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] a defined position not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (63) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
AA for storage rack
Funktion (Function): Curing Board put in storage rack when the number is reached 10 Cushion
[Prozeß KAB Midfill (Silicone 7 Cushions are damaged [Glueing + Curing, Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] when placing the board in Cu- not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (63) QM IAU / IAU, QM IAU / IAT;
committee ring Storage Rack sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
AA for storage rack
Funktion (Function): Silicone line cure by time
silicone line does not cure
(full) (NOT RELEVANT)
Funktion (Function): remove from Cushions Storage Rack and Table Light transport
Cushions are when remo-
ving them from Storage
Rack / Transport to the Light
Table is damaged ( NOT RE-
LEVANT )
Cushions are when remo-
ving them from Storage
Rack / Transport to the Light
Table dirty ( NOT RELE-
VANT )
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Glueing + Curing, Label Cus- Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] hion] specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
process stop (only losing ti- not met the standards speci- drawing UPS with delivered parts QM, QM IAT / IAU
me , no rework the product fied
Insert)] [Glueing + Curing, Silicone In- Maßnahmenstand - Anfang (Initial state): 20.09.2012
committee sert] specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
not met the standards speci- drawing UPS with delivered parts QM, QM IAT / IAU
fied
[Glueing + Curing, 2-Compo- Maßnahmenstand - Anfang (Initial state): 20.09.2012
nent Glue] specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
not met the standards speci- drawing UPS with delivered parts QM, QM IAT / IAU
fied
review of the silicone line employee qualifications: to 2 control plan: visual exami- 2 (28) QM IAU / IAU, QM IAU / IAT;
width / thickness make sure that exclusively nation at the beginning of the QM, QM IAT / IAU
and demonstrably trained per- next part of periodic review BMG Freigabe
sonnel this process step im- process / process step Light unbearbeitet (untouched)
plemented (quality matrix) Table
AA developing and implemen- control plan 100% came-
ting in practice ra inspection (DSS )
contour verification NOK employee qualifications: to 2 control plan: visual examinati- 2 (28) QM IAU / IAU, QM IAU / IAT;
make sure that exclusively on at the beginning of the QM, QM IAT / IAU
and demonstrably trained per- next sub-process periodic re- BMG Freigabe
sonnel this process step im- view unbearbeitet (untouched)
QM IAU / IAU, QM IAU / IAT control plan 100% camera in-
AA developing and implemen- spection (DSS )
ting in practice QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU
review of the silicone trace employee qualifications: to 2 control plan: visual examinati- 2 (28) QM IAU / IAU, QM IAU / IAT;
thickness periodic testing not make sure that exclusively on at the beginning of the QM, QM IAT / IAU
performed and demonstrably trained per- next part of the process BMG Freigabe
ting in practice
QM, QM IAT / IAU
Systemelement (System element): CNC Sewing
Merkmal (Characteristic): Faltspezifikation optionaler Bauteile erfüllen
[Prozeß KAB Midfill (Silicone 7 specification of folding optio- [Operator] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] nal components not met not folded optional com- AA developing and implemen- 2 control plan: 100% visual in- 2 (28) QM IAU / IAU, QM IAU / IAT;
committee ponents according to dra- ting in practice spection in the sub-process QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 5 wing specification "Light Table"
QM, QM IAT / IAU BMG Freigabe
Insert)] QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
unnecessary prolongation of employee qualifications: to
the cycle time / lead time make sure that exclusively
Merkmal (Characteristic): <S> Positionierung der Nähte
[Prozeß KAB Midfill (Silicone 10 positionof seam NOK S [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] sorik)] maintenance plan 3 process monitoring by ope- 2 (60) Gottschalk, Markus, TX1;
Airbag inflates when trigge- thread run NOK rator according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
880.BF , use safety ) specification: process monito- QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 ring by machine / software control plan 100% camera in-
Insert)] Gottschalk, Markus, TX1 spection (DSS )
life too short (LAH.DUM.880. QM IAU / IAU, QM IAU / IAT
BF)
[Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 16.07.2013
[Prozeß KAB Midfill (Silicone 10 sorik)] AA developing and implemen- 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Insert)] stopped sewing ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
filling gas flows directly into QM, QM IAT / IAU
QM, QM IAT / IAU ding to AA
vehicle interior
[Prozeß KAB Midfill (Silicone 7 employee qualifications: to
Insert)] make sure that exclusively
committee and demonstrably trained per-
Insert)]
unnecessary prolongation of QM IAU / IAU, QM IAU / IAT
the cycle time / lead time specification: process mo-
nitoring by machine / soft-
ware
needel selection NOK AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
ting in practice tor according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
employee training plan control plan: 100% visual
QM, QM IAT / IAU inspection
maintenance plan QM IAU / IAU, QM IAU / IAT
TE2 Wien, TE2 Wien needle selection compared

with drawing
periodic changing the needle
after maintenance plan QM IAU / IAU, QM IAU / IAT

Merkmal (Characteristic): <S> Position optionaler Bauteile
[Prozeß KAB Midfill (Silicone 10 incorrect position of optional S [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] components positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. ponents faulty TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
880.BF , use safety ) technical specifications: a QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 constructive account of the implementation of machine
Insert)] design tool acceptance results / mainte-
seek time is too long (LAH. Gottschalk, Markus, TX1 nance plan
DUM.880.BF) QM IAU / IAU, QM IAU / IAT
Insert)] incorrect position of optional [Tooling] Gottschalk, Markus, TX1 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
inflation too long ( LAH.DUM. components positioning and fixing airbag unbearbeitet (untouched)
880.BF ) and optional further com-
[Prozeß KAB Midfill (Silicone 10 ponents faulty
Insert)]
BF)
Insert)]
vehicle interior
Insert)]
separating parts are genera-
ted upon deployment (LAH.
DUM.880.BF)
Insert)]
committee
Merkmal (Characteristic): <S> Vollständigkeit optionaler Bauteile
[Prozeß KAB Midfill (Silicone 10 incompleteness optional com- S [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] ponents sorik)] maintenance plan 3 process monitoring by ope- 2 (60) Gottschalk, Markus, TX1;
Airbag inflates when trigge- optionally: not check the pre- rator according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. sence and the sequence of TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
880.BF , use safety ) the air bag, and optionally fur- specifications: sensor QM IAU / IAU, QM IAU / IAT
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 ther components scanning control plan: periodic sen-
BMG Freigabe
Insert)] Gottschalk, Markus, TX1 sor test with test pieces unbearbeitet (untouched)
seek time is too long (LAH. QM, QM IAT / IAU
specification: process monito-
DUM.880.BF)
ring by machine / software
Insert)]
inflation too long ( LAH.DUM. periodic errors provocation
880.BF ) QM IAU / IAU, QM IAU / IAT
Insert)]
BF)
Insert)]
vehicle interior
Insert)]
committee
Merkmal (Characteristic): <S> Orientierung Naht zur Silikonspur bei Naht in Silikonspur
[Prozeß KAB Midfill (Silicone 10 wrong position of the seam S [Tooling] Maßnahmenstand - Anfang (Initial state): 09.01.2013
Insert)] to the silicon track incorrect positioning silicone technical specifications: a 6 process monitoring by opera- 2 (120) Gottschalk, Markus, TX1;
Airbag inflates when trigge- track to seam course (at vor- constructive account of the tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. handner silicone track) design tool TE2 Wien, TE2 Wien
880.BF , use safety ) QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 10 implementation of machine
Insert)] maintenance plan acceptance results / mainte-
seek time is too long (LAH. TE2 Wien, TE2 Wien nance plan
[Prozeß KAB Midfill (Silicone 10 control plan 100% camera in-
Insert)] spection (DSS )
880.BF )
Insert)]
BF)
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
Insert)]
committee
Merkmal (Characteristic): <S> CNC Sewing Machine mit Threads bestücken
[Prozeß KAB Midfill (Silicone 7 not equipped with Bobbin [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] thread and / or needle thread not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (63) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
process stop with n.i.O. cha- plemented (quality matrix) machine downtime in the
racterization (part blocked) next part process
Insert)] ting in practice control plan: 100% visual in-
process upset - no further pro- spection in the sub-process
cessing possible QM, QM IAT / IAU "Light Table"
sorik)] maintenance plan 3 process monitoring by opera- 2 (42) QM IAU / IAU, QM IAU / IAT;
not guarantee delivery tor according to AA TE2 Wien, TE2 Wien
threads TE2 Wien, TE2 Wien
periodic errors provocation QM IAU / IAU, QM IAU / IAT BMG Freigabe
(bobbin thread monitor
thread)
[Prozeß KAB Midfill (Silicone 10 equipped with false Bobbin S [Operator] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] thread and / or incorrect need- wrong selection of bobbin / AA developing and implemen- 2 visual inspection at the begin- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigger le thread neddle thread ting in practice ning of the next sub process QM, QM IAT / IAU
not ( LAH.DUM.880.BF )
QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)] employee qualifications: to visual inspection in sub pro-
Airbag inflates when trigge- make sure that exclusively cess "Inspection" according
ring undefined ( LAH.DUM. and demonstrably trained per- AA
880.BF , use safety ) sonnel this process step im- QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 control plan: 100% inspec-
Insert)] QM IAU / IAU, QM IAU / IAT tion
DUM.880.BF)
first piece testing/ check start
of shift / change of material
[Prozeß KAB Midfill (Silicone 10 ^ ^S ^ ^ ^ ^ [...] ^ ^ ^
Insert)] equipped with false Bobbin [...] QM IAU / IAU, QM IAU / IAT 2 2 (40) [...]
inflation too long ( LAH.DUM. thread and / or incorrect need- QM, QM IAT / IAU
880.BF ) le thread [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
[Prozeß KAB Midfill (Silicone 10 not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
Insert)] sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
life too short (LAH.DUM.880. and demonstrably trained per- TE2 Wien, TE2 Wien
BF) TE2 Wien, TE2 Wien
next part process
filling gas flows directly into TE2 Wien, TE2 Wien
vehicle interior AA developing and implemen-
ting in practice control plan: 100% visual in-
[Prozeß KAB Midfill (Silicone 10 spection in the sub-process
Insert)] QM, QM IAT / IAU "Light Table"
separating parts are genera- QM IAU / IAU, QM IAU / IAT
DUM.880.BF)
Merkmal (Characteristic): <S> Cushion/Cover und optional weitere Bauteile in CNC Sewing Machine IO
[Prozeß KAB Midfill (Silicone 10 inserted Cushion / Cover S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] and / or optionally other com- positioned air bag and AA developing and implemen- 2 sensor scan for location 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- ponents in wrong order other optional components is ting in practice detection QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. incorrect / (jig) QM, QM IAT / IAU;
880.BF , use safety ) QM, QM IAT / IAU TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 employee qualifications: to no sewing start possible
BMG Freigabe
Insert)] make sure that exclusively TE2 Wien, TE2 Wien unbearbeitet (untouched)
life too short (LAH.DUM.880. and demonstrably trained per-
sonnel this process step im- control plan: 100% inspec-
BF)
plemented (quality matrix) tion
Insert)]
filling gas flows directly into specifications: positioning via control plan: periodic sen-
vehicle interior sewing clamp sor test with test pieces
[Prozeß KAB Midfill (Silicone 10 Gottschalk, Markus, TX1 QM, QM IAT / IAU
Insert)]
installation in the vehicle in-
not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
correctly possible (not visible
sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
) ( LAH.DUM.880.BF )
Insert)] machine downtime in the
Insert)] AA developing and implemen-
unnecessary prolongation of
spection in the sub-process
the cycle time / lead time QM, QM IAT / IAU "Light Table"
sorik)] maintenance plan 3 process monitoring by ope- 2 (60) Gottschalk, Markus, TX1;
optionally: not check the pre- rator according to AA QM IAU / IAU, QM IAU / IAT;
sence and the sequence of TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
the air bag, and optionally fur- specifications: sensor QM IAU / IAU, QM IAU / IAT
TE2 Wien, TE2 Wien
ther components scanning control plan: periodic sen-
BMG Freigabe
Gottschalk, Markus, TX1 sor test with test pieces
specification: process monito- QM, QM IAT / IAU
periodic errors provocation
inserted incorrect optional
components (not relevant)
[Prozeß KAB Midfill (Silicone 10 optional additional com- S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ponents not loaded complete positioned air bag and AA developing and implemen- 2 sensor scan for location 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- other optional components is ting in practice detection QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. incorrect / (jig) QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
BF)
Insert)]
Insert)]
process stop (only losing ti- next part process
me , no rework the product QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone ting in practice control plan: 100% visual in-
7
committee
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
Gottschalk, Markus, TX1 sor test with test pieces unbearbeitet (untouched)
[Prozeß KAB Midfill (Silicone 10 Cushion / Cover is not in the S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] correct position loaded into does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- CNC Sewing Machine and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. ponents TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
life too short (LAH.DUM.880. Gottschalk, Markus, TX1 nance plan
BF) QM IAU / IAU, QM IAU / IAT
Insert)]
vehicle interior
^ ^ ^ ^ ^S [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
[Prozeß KAB Midfill (Silicone 10 Cushion / Cover is not in the positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
[...] correct position loaded into and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
CNC Sewing Machine ponents faulty TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
technical specifications: a QM IAU / IAU, QM IAU / IAT
Insert)] constructive account of the implementation of machine
committee design tool acceptance results / mainte-
Gottschalk, Markus, TX1 nance plan
positioned air bag and AA developing and implemen- 2 sensor scan for location 2 (40) Gottschalk, Markus, TX1;
other optional components is ting in practice detection QM IAU / IAU, QM IAU / IAT;
incorrect / (jig) QM, QM IAT / IAU;
QM, QM IAT / IAU TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
employee qualifications: to no sewing start possible
BMG Freigabe
make sure that exclusively TE2 Wien, TE2 Wien unbearbeitet (untouched)
specifications: positioning via control plan: periodic sen-
sewing clamp sor test with test pieces
Gottschalk, Markus, TX1 QM, QM IAT / IAU
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
QM, QM IAT / IAU "Light Table"
[Prozeß KAB Midfill (Silicone 10 optional additional com- S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ponents not installed in the does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- correct position and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
committee Gottschalk, Markus, TX1 nance plan
Insert)] [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
life too short (LAH.DUM.880. positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
BF) and optional further com-
TE2 Wien, TE2 Wien tor according to AA QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 ponents faulty TE2 Wien, TE2 Wien
filling gas flows directly into constructive account of the implementation of machine
vehicle interior design tool acceptance results / mainte-
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
Merkmal (Characteristic): <S> Cushion/Cover und optional weitere Bauteile mittels CNC Sewing Machine vernähen
[Prozeß KAB Midfill (Silicone 10 Cushion / Cover and optional S [Technican] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] further components with a fal- Incorrect setting of the machi- AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- se seam sewn ( position air ne 2 - herons, 3 - heron ting in practice AA QM, QM IAT / IAU
ring undefined ( LAH.DUM. bag components seam)
880.BF , use safety ) QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 employee qualifications: to implementation of machine
Insert)] make sure that exclusively acceptance results / mainte-
life too short (LAH.DUM.880. and demonstrably trained per- nance plan
BF) sonnel this process step im- QM IAU / IAU, QM IAU / IAT
vehicle interior
^ ^ ^S [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
[Prozeß KAB Midfill (Silicone 7 Cushion / Cover and optional sorik)] maintenance plan 2 process monitoring by opera- 3 (60) Gottschalk, Markus, TX1;
Insert)]
further components with a fal- not sewn custom sewing tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
committee TE2 Wien, TE2 Wien
se seam sewn ( position air ding to AA TE2 Wien, TE2 Wien
bag components seam) specification: process mo-
ware
[Prozeß KAB Midfill (Silicone 10 Cushion / Cover and optional S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] further components not com- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- pletely sewed and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
filling gas flows directly into and optional further com-
vehicle interior ponents faulty TE2 Wien, TE2 Wien
Incorrect setting of the machi- AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
ne 2 - herons, 3 - heron ting in practice AA QM, QM IAT / IAU
employee qualifications: to implementation of machine
make sure that exclusively acceptance results / mainte-
and demonstrably trained per- nance plan
sonnel this process step im- QM IAU / IAU, QM IAU / IAT
control plan: 100% inspec-
QM IAU / IAU, QM IAU / IAT tion
not observe yarn length of employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
the lower thread make sure that exclusively rent subprocess QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
plemented (quality matrix) process monitoring by opera-
tor according to AA
ting in practice control plan 100% visual in-
spection in the process
QM, QM IAT / IAU
periodic replacement of the
bobbin
not observe yarn length of employee qualifications: to 3 machine downtime in the cur- 3 (90) Gottschalk, Markus, TX1;
the upper thread make sure that exclusively rent subprocess QM IAU / IAU, QM IAU / IAT;
and demonstrably trained per- QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
sonnel this process step im- TE2 Wien, TE2 Wien
BMG Freigabe
tor according to AA
ting in practice control plan 100% visual in-
spection in the process
QM, QM IAT / IAU
specifications : thread moni-
tor
sorik)] maintenance plan 2 process monitoring by opera- 3 (60) Gottschalk, Markus, TX1;
not sewn custom sewing tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
ding to AA TE2 Wien, TE2 Wien
specification: process mo-
ware
Cushion / Cover and optio-
nal further components with
the wrong stitch density sutu-
red ( NOT RELEVANT )
[Prozeß KAB Midfill (Silicone 10 Cushion / Cover and optional- S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ly other components outside does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- of the silicone trace stitched and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. (only with seams within the si- ponents TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
880.BF , use safety ) licon track) technical specifications: a QM IAU / IAU, QM IAU / IAT
BMG Freigabe
TE2 Wien, TE2 Wien
BMG Freigabe
^ ^ ^ ^ ^S [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
[Prozeß KAB Midfill (Silicone 7 Cushion / Cover and optional- not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
Insert)] ly other components outside sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
committee of the silicone trace stitched and demonstrably trained per- TE2 Wien, TE2 Wien
(only with seams within the si- TE2 Wien, TE2 Wien
licon track) plemented (quality matrix) machine downtime in the
next part process
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 stitched cushion / cover and S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] optionally other components does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- too close to the edge of the si- and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. licon line ponents TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 stitched cushion / cover and [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] optional further components does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- with incorrect thread tension and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
filling gas flows directly into and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
settings ting in practice tor according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
employee training plan control plan: 100% inspec-
QM, QM IAT / IAU tion
TE2 Wien, TE2 Wien

after maintenance plan
not observe defined machine AA developing and implemen- 2 process monitoring by ope- 2 (40) QM IAU / IAU, QM IAU / IAT;
settings ting in practice rator according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ BMG Freigabe
employee qualifications: to
[Prozeß KAB Midfill (Silicone 7 stitched cushion / cover and [Operator] 2 QM IAU / IAU, QM IAU / IAT 2 (40) unbearbeitet (untouched)
make sure that exclusively
Insert)] optional further components not observe defined machine
committee with incorrect thread tension settings
maintenance plan
TE2 Wien, TE2 Wien
wrong selection of bobbin / AA developing and implemen- 2 visual inspection at the begin- 2 (40) QM IAU / IAU, QM IAU / IAT;
neddle thread ting in practice ning of the next sub process QM, QM IAT / IAU
employee qualifications: to visual inspection in sub pro-
make sure that exclusively cess "Inspection" according
and demonstrably trained per- AA
sonnel this process step im- QM, QM IAT / IAU
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
sorik)] AA developing and implemen- 2 process stop due to the 2 (40) Gottschalk, Markus, TX1;
needle breakage ting in practice thread monitor QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
BMG Freigabe
BMG Freigabe Termin? (Deadline?)
employee training plan process monitoring by opera-
QM, QM IAT / IAU tor / machine / software accor-
ding to AA
BMG Freigabe
(unbearbeitet (untouched)) QM IAU / IAU, QM IAU / IAT
needle exchange min. to BMG Freigabe
start of shift and when requi- (unbearbeitet (untouched))
red
QM, QM IAT / IAU
BMG Freigabe
specifications: thread monitor
BMG Freigabe
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

[Prozeß KAB Midfill (Silicone 10 stitched cushion / cover and S [Technican] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] optional further components not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- with skipped stitches settings ting in practice tor according to AA QM, QM IAT / IAU;
880.BF , use safety ) QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 employee training plan control plan: 100% inspec-
Insert)] QM, QM IAT / IAU tion
life too short (LAH.DUM.880. QM IAU / IAU, QM IAU / IAT
maintenance plan
BF)
TE2 Wien, TE2 Wien
Insert)] periodic changing the needle
filling gas flows directly into after maintenance plan
vehicle interior QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 7 ^ ^S [Operator] ^ Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] stitched cushion / cover and wrong selection of bobbin /
committee optional further components AA developing and implemen- 2 visual inspection at the begin- 2 (40) QM IAU / IAU, QM IAU / IAT;
with skipped stitches
QM, QM IAT / IAU
sorik)] AA developing and implemen- 2 process stop due to the 2 (40) Gottschalk, Markus, TX1;
needle breakage ting in practice thread monitor QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
BMG Freigabe
BMG Freigabe Termin? (Deadline?)
employee training plan process monitoring by opera-
QM, QM IAT / IAU tor / machine / software accor-
ding to AA
BMG Freigabe
(unbearbeitet (untouched)) QM IAU / IAU, QM IAU / IAT
needle exchange min. to BMG Freigabe
start of shift and when requi- (unbearbeitet (untouched))
red
QM, QM IAT / IAU
BMG Freigabe
specifications: thread monitor
BMG Freigabe
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

[Prozeß KAB Midfill (Silicone 10 stitched cushion / cover and S [Technican] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] optional further components Incorrect setting of the machi- AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- with faulty overlag ne 2 - herons, 3 - heron ting in practice AA QM, QM IAT / IAU
ring undefined ( LAH.DUM.
vehicle interior
Insert)]
committee ting in practice tor according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

[Prozeß KAB Midfill (Silicone 10 stitched cushion / cover and S [Sewing Threads (Bobbin + Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] optional further components Needle)] employee training plan 2 thread monitor: when pro- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- with thread breakage thread breakage cess is interrupted QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. QM, QM IAT / IAU
QM, QM IAT / IAU
880.BF , use safety ) BMG Freigabe QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 (unbearbeitet (untouched)) BMG Freigabe
Insert)] AA developing and implemen- (unbearbeitet (untouched))
life too short (LAH.DUM.880. ting in practice part with declared error NOK
BF)
[Prozeß KAB Midfill (Silicone 10 BMG Freigabe ble?)
Insert)] (unbearbeitet (untouched)) Termin? (Deadline?)
filling gas flows directly into (unbearbeitet (untouched))
vehicle interior specifications : thread moni-
tor
Insert)] Gottschalk, Markus, TX1
committee BMG Freigabe
wrong selection of bobbin / AA developing and implemen- 2 visual inspection at the begin- 2 (40) QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
needel selection NOK
^ ^ ^ ^ ^S ^ ^ AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 7 stitched cushion / cover and [Technican] ting in practice tor according to AA QM, QM IAT / IAU;
Insert)] optional further components needel selection NOK TE2 Wien, TE2 Wien
committee with thread breakage BMG Freigabe

with drawing

Merkmal (Characteristic): <F> Identität Bobbin / Neddle Thread
[Prozeß KAB Midfill (Silicone 10 erroneous identity bobbin / F [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] neddle thread not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
inflation too long ( LAH.DUM. sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
880.BF ) and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
identification of the airbag next part process
and / or components only to TE2 Wien, TE2 Wien
a limited extent AA developing and implemen-
[Prozeß KAB Midfill (Silicone 6 identity Cushion faulty F [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (54) QM IAU / IAU, QM IAU / IAT;
process stop (rework on pro- sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
duct possible / required) and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
identification is not possible next part process
of the airbag and / or of com- TE2 Wien, TE2 Wien
ponents AA developing and implemen-
a limited extent
Insert)]
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Sewing Threads (Bobbin + Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] Needle)] specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
Insert)] [Tracebility system] Maßnahmenstand - Anfang (Initial state): 17.07.2012
committee specify steps wrong specifications: adoption and 2 validation of software com- 2 (28) Gottschalk, Markus, TX1;
adaptation / adaptation of pro- ponents state-of-the-art tech- Massinger, Jörgen Michael,
ven series HW and SW com- nology IT;
ponets (for examble AU 316) QM IAU / IAU, QM IAU / IAT
implementation of machine
PASS system after release acceptance results / mainte-
of the validated algorithms sa- nance plan
fed against changes QM IAU / IAU, QM IAU / IAT
sorik)] AA developing and implemen- 2 process monitoring by opera- 2 (28) Gottschalk, Markus, TX1;
not performed sewing ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
ding to AA QM, QM IAT / IAU
QM, QM IAT / IAU
ware
Funktion (Function): recording of test reports
[Prozeß KAB Midfill (Silicone 10 wrong / insufficient / no re- [Tracebility system] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] cord of test reports records results of the pro- specifications: adoption and 2 plausibility check of data 2 (40) Gottschalk, Markus, TX1;
could not recognize the cess lead to faulty adaptation / adaptation of pro- Massinger, Jörgen Michael,
locking state of the Securing Massinger, Jörgen Michael, IT
Unit at assembly ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 6 results
identification is not possible PASS system after release
of the airbag and / or of com- of the validated algorithms sa-
ponents fed against changes
[Prozeß KAB Midfill (Silicone 6 Massinger, Jörgen Michael, IT
identification of the airbag records results of the pro- specifications: adoption and 2 plausibility check of data 2 (40) Gottschalk, Markus, TX1;
and / or components only to cess cycle defective / not on adaptation / adaptation of pro- Massinger, Jörgen Michael,
a limited extent Massinger, Jörgen Michael, IT
Insert)] results
identification of the airbag QM, QM IAT / IAU unbearbeitet (untouched)
and / or components only PASS system after release
with increased effor of the validated algorithms sa-
fed against changes
Systemelement (System element): Manual Sewing
[Prozeß KAB Midfill (Silicone 10 positioning of the seams faul- S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ty positioned seam position / AA developing and implemen- 3 control plan: visual examinati- 5 (150) Gottschalk, Markus, TX1;
Airbag inflates when trigge- fabric edge flawed ting in practice on in the subprocess "Final QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. Inspection" QM, QM IAT / IAU
880.BF , use safety ) QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 ^ ^ ^S ^ ^ employee qualifications: to ^ ^ ^ ^
Insert)] positioning of the seams faul- [Operator] make sure that exclusively 3 control plan 100% came- 5 (150) BMG Freigabe
Default deployment direction ty positioned seam position / and demonstrably trained per- ra inspection (DSS ) unbearbeitet (untouched)
is not complied with (LAH. fabric edge flawed sonnel this process step im- QM IAU / IAU, QM IAU / IAT
DUM.880.BF , use safety) plemented (quality matrix)
Insert)] specifications: positioning
seek time is too long (LAH. via sewing clamp
DUM.880.BF)
specifications: edge stop
Insert)]
inflation too long ( LAH.DUM. Gottschalk, Markus, TX1
880.BF ) [Technican] Maßnahmenstand - Anfang (Initial state): 04.02.2013
[Prozeß KAB Midfill (Silicone 10 edge stop faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
Insert)] ting in practice nation in the subprocess QM, QM IAT / IAU
filling gas flows directly into "Final Inspection"
vehicle interior
Insert)]
committee
Merkmal (Characteristic): <S> Nähspezifikation
[Prozeß KAB Midfill (Silicone 10 specification of sewing NOK [Sewing Threads (Bobbin + Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] Needle)] employee training plan 2 thread monitor: when pro- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- thread breakage cess is interrupted QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
BMG Freigabe
Default deployment direction ting in practice part with declared error NOK
is not complied with (LAH.
DUM.880.BF , use safety) ble?)
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 (unbearbeitet (untouched)) Termin? (Deadline?)
Insert)] (unbearbeitet (untouched))
seek time is too long (LAH. specifications : thread moni-
DUM.880.BF) tor
[Prozeß KAB Midfill (Silicone 10 Gottschalk, Markus, TX1
inflation too long ( LAH.DUM. (unbearbeitet (untouched))
880.BF ) [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
[Prozeß KAB Midfill (Silicone 10 not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
Insert)] settings ting in practice tor according to AA QM, QM IAT / IAU;
filling gas flows directly into TE2 Wien, TE2 Wien
vehicle interior QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 employee qualifications: to control plan 100% came-
Insert)] make sure that exclusively ra inspection (DSS )
committee and demonstrably trained per- QM IAU / IAU, QM IAU / IAT
maintenance plan
TE2 Wien, TE2 Wien
positioned seam position / AA developing and implemen- 3 control plan: visual examinati- 5 (150) Gottschalk, Markus, TX1;
fabric edge flawed ting in practice on in the subprocess "Final QM IAU / IAU, QM IAU / IAT;
Inspection" QM, QM IAT / IAU
QM, QM IAT / IAU
make sure that exclusively control plan 100% came-
and demonstrably trained per- ra inspection (DSS )
S specifications: positioning
via sewing clamp
stitch density faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
ting in practice nation in the subprocess QM, QM IAT / IAU
QM, QM IAT / IAU "Final Inspection" BMG Freigabe
make sure that exclusively control plan 100% camera in-
and demonstrably trained per- spection (DSS )
thread tension faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
edge stop faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
needel selection NOK AA developing and implemen- 2 control plan: 100% visual in- 2 (40) QM IAU / IAU, QM IAU / IAT;
ting in practice spection QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^S ^ ^ ^ ^ ^ BMG Freigabe
employee training plan needle selection compared
[Prozeß KAB Midfill (Silicone 7 specification of sewing NOK [Technican] 2 2 (40) unbearbeitet (untouched)
QM, QM IAT / IAU with drawing
Insert)] needel selection NOK
committee maintenance plan QM IAU / IAU, QM IAU / IAT
TE2 Wien, TE2 Wien

[Device] Maßnahmenstand - Anfang (Initial state): 26.09.2012
sewing paramter faulty maintenance plan 3 process monitoring by opera- 3 (90) Gottschalk, Markus, TX1;
tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
specifications: stiching para- QM IAU / IAU, QM IAU / IAT
BMG Freigabe
meter observation (stiching
strain...)
thread run NOK maintenance plan 3 process monitoring by opera- 2 (60) Gottschalk, Markus, TX1;
tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
specification: process monito- QM IAU / IAU, QM IAU / IAT
BMG Freigabe
ring by machine / software control plan 100% came-
Gottschalk, Markus, TX1 ra inspection (DSS )
stopped sewing AA developing and implemen- 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
ware
Merkmal (Characteristic): <S> Sewing Machine mit Threads bestücken
process stop with n.i.O. cha- sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
racterization (part blocked) and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
process upset - no further pro- next part process
cessing possible TE2 Wien, TE2 Wien
not guarantee delivery maintenance plan 3 process monitoring by opera- 2 (42) QM IAU / IAU, QM IAU / IAT;
threads tor according to AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
Insert)] thread and / or incorrect need- wrong selection of bobbin / employee qualifications: to 2 control plan: visual examinati- 2 (40) Konstruktion, TE2;
damage to the airbag during le thread neddle thread make sure that exclusively on at the beginning of the QM IAU / IAU, QM IAU / IAT;
transport possible ( LAH. and demonstrably trained per- next part of the process QM, QM IAT / IAU
DUM.880.BF ) sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
[Prozeß KAB Midfill (Silicone 5 plemented (quality matrix) in Umsetzung (in progress)
QM IAU / IAU, QM IAU / IAT (unbearbeitet (untouched))
the cycle time / lead time BMG Freigabe control plan: visual examinati-
(unbearbeitet (untouched)) on in the subprocess "Final
Insert)] AA developing and implemen- Inspection"
committee ting in practice QM IAU / IAU, QM IAU / IAT
(unbearbeitet (untouched)) control plan 100% camera in-
constructive: various Colors spection (DSS )
of threads QM IAU / IAU, QM IAU / IAT
Konstruktion, TE2 BMG Freigabe
(abgeschlossen (completed))
Merkmal (Characteristic): Positionierung Cushion in Sewing Machine
[Prozeß KAB Midfill (Silicone 7 Cushion is not inserted in [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] the correct position positioned seam position / AA developing and implemen- 3 control plan: visual examinati- 5 (105) Gottschalk, Markus, TX1;
committee fabric edge flawed ting in practice on in the subprocess "Final QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
via sewing clamp
Merkmal (Characteristic): <S> Cushion mittels CNC Sewing Machine vernähen
Cushion with a false se-
am sewn ( not relevant in the
manual process )
[Prozeß KAB Midfill (Silicone 10 Cushion not completely S [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] sewn ( thread breakage ) not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- settings ting in practice tor according to AA QM, QM IAT / IAU;
^ ^ ^S ^ ^ ^ ^ ^ BMG Freigabe
Cushion not completely [Operator] 2 2 (40) unbearbeitet (untouched)
sewn ( thread breakage ) not observe defined machine
Default deployment direction and demonstrably trained per- QM IAU / IAU, QM IAU / IAT
settings
is not complied with (LAH. sonnel this process step im-
TE2 Wien, TE2 Wien
DUM.880.BF)
Insert)]
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 process monitoring by opera-
Insert)] tor according to AA
filling gas flows directly into QM IAU / IAU, QM IAU / IAT
ting in practice
QM, QM IAT / IAU
bobbin
the upper thread make sure that exclusively rent subprocess QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
tor according to AA
ting in practice
QM, QM IAT / IAU
thread monitor checks are
proved for the upper thread
during stitch
QM, QM IAT / IAU
positioned seam position / AA developing and implemen- 3 control plan: visual examinati- 5 (150) Gottschalk, Markus, TX1;
fabric edge flawed ting in practice on in the subprocess "Final QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
via sewing clamp
edge stop faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
needle breakage AA developing and implemen- 2 control plan: 100% visual 2 (40) QM IAU / IAU, QM IAU / IAT;
ting in practice inspection QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
employee training plan control plan 100% came-
QM, QM IAT / IAU ra inspection (DSS )
TE2 Wien, TE2 Wien

[Prozeß KAB Midfill (Silicone 10 Cushion sewed with incor- S [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] rect thread tension not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
BMG Freigabe
TE2 Wien, TE2 Wien
DUM.880.BF)
stitch density faulty employee qualifications: to 3 control plan: visual examinati- 3 (90) QM IAU / IAU, QM IAU / IAT
Insert)]
inflation too long ( LAH.DUM. make sure that exclusively on in the subprocess "Final BMG Freigabe
880.BF ) and demonstrably trained per- Inspection" unbearbeitet (untouched)
sonnel this process step im- control plan 100% camera in-
plemented (quality matrix) spection (DSS )
Insert)]
filling gas flows directly into [Technican] Maßnahmenstand - Anfang (Initial state): 04.02.2013
vehicle interior stitch density faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
make sure that exclusively control plan 100% camera in-
and demonstrably trained per- spection (DSS )
not observe defined machine
settings
^ ^ ^ ^ ^S ^ ^ AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 Cushion sewed with incor- [Technican] ting in practice tor according to AA QM, QM IAT / IAU;
Insert)] rect thread tension not observe defined machine TE2 Wien, TE2 Wien
filling gas flows directly into settings BMG Freigabe
vehicle interior employee qualifications: to control plan 100% came-
make sure that exclusively ra inspection (DSS )
and demonstrably trained per- QM IAU / IAU, QM IAU / IAT
maintenance plan
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien

[Prozeß KAB Midfill (Silicone 10 Cushion sewed with incor- [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] rect thread tension not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
BMG Freigabe
TE2 Wien, TE2 Wien
DUM.880.BF)
thread tension commands employee qualifications: to 3 control plan: visual examinati- 3 (90) QM IAU / IAU, QM IAU / IAT
Insert)]
way make sure that exclusively on in the subprocess "Final
inflation too long ( LAH.DUM. BMG Freigabe
880.BF ) and demonstrably trained per- Inspection" unbearbeitet (untouched)
Insert)]
vehicle interior thread tension faulty AA developing and implemen- 2 control plan: visual exami- 2 (40) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
employee qualifications: to control plan 100% came-
make sure that exclusively ra inspection (DSS )
maintenance plan
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien

[Prozeß KAB Midfill (Silicone 10 Cushion sewed with skipped S [Technican] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] stitches not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
BMG Freigabe
TE2 Wien, TE2 Wien
DUM.880.BF)
Insert)]
880.BF )
Insert)]
vehicle interior
[Prozeß KAB Midfill (Silicone 10 Cushion sewed with faulty S [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] About seam / overlap / faulty locking area AA developing and implemen- 3 control plan: visual examinati- 2 (60) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- locking area ting in practice on in the subprocess "Final QM, QM IAT / IAU
ring undefined ( LAH.DUM. Inspection"
880.BF , use safety ) QM, QM IAT / IAU BMG Freigabe
Default deployment direction and demonstrably trained per-
[Prozeß KAB Midfill (Silicone 10 ^ ^ ^S ^ ^ QM IAU / IAU, QM IAU / IAT ^ ^ ^ ^ ^
Insert)] Cushion sewed with faulty [Operator] 3 QM IAU / IAU, QM IAU / IAT 2 (60) BMG Freigabe
seek time is too long (LAH. About seam / overlap / faulty locking area unbearbeitet (untouched)
DUM.880.BF) locking area
Insert)]
880.BF )
Insert)]
vehicle interior
Merkmal (Characteristic): <F> Identität Threads
[Prozeß KAB Midfill (Silicone 10 identity Threads faulty F [Technican] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] not enter batch number employee qualifications: to 2 4 (80) QM IAU / IAU, QM IAU / IAT;
filling gas flows directly into make sure that exclusively QM, QM IAT / IAU
vehicle interior and demonstrably trained per- BMG Freigabe
identification is not possible QM IAU / IAU, QM IAU / IAT
of the airbag and / or of com-
ting in practice
no identity Threads (not re-
levant)
damage to the airbag during sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
transport possible ( LAH. and demonstrably trained per- TE2 Wien, TE2 Wien
DUM.880.BF ) TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 5 plemented (quality matrix) machine downtime in the
Insert)] next part process
unnecessary prolongation of TE2 Wien, TE2 Wien
the cycle time / lead time AA developing and implemen-
identification is not possible
of the airbag and / or of com-
ponents
no identity Cushion (not re-
levant)
identification is not possible cess lead to faulty adaptation / adaptation of pro- Massinger, Jörgen Michael,
of the airbag and / or of com- Massinger, Jörgen Michael, IT
ponents ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
process stop with n.i.O. cha- PASS system after release
racterization (part blocked) of the validated algorithms sa-
fed against changes
[Tracebility system] Maßnahmenstand - Anfang (Initial state): 20.09.2012
records results of the pro- specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
cess cycle defective / not on adaptation / adaptation of pro- Massinger, Jörgen Michael,
ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
results
QM, QM IAT / IAU unbearbeitet (untouched)
PASS system after release
of the validated algorithms sa-
fed against changes
not performed sewing AA developing and implemen- 2 process monitoring by opera- 2 (28) Gottschalk, Markus, TX1;
ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
ware
unnecessary prolongation of not met the standards speci- drawing UPS with delivered parts QM, QM IAT / IAU
the cycle time / lead time fied
not guarantee delivery maintenance plan 3 process monitoring by opera- 2 (30) QM IAU / IAU, QM IAU / IAT;
threads tor according to AA TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
Systemelement (System element): Light Table Inspection
Merkmal (Characteristic): <S> Complete Components
[Prozeß KAB Midfill (Silicone 7 Complete Components NOK S
Insert)]
committee
Merkmal (Characteristic): <S> Complete Seam
[Prozeß KAB Midfill (Silicone 5 Complete Seam NOK (stitch S
Insert)] density IO, thread damage =
unnecessary prolongation of 0, error stitch = 0)
the cycle time / lead time
Merkmal (Characteristic): <S> Übernaht / Naht vorhanden
[Prozeß KAB Midfill (Silicone 7 overlap seam / seam availa- S
Insert)] ble NOK
committee
Merkmal (Characteristic): <S> Nahtüberstand
[Prozeß KAB Midfill (Silicone 7 sewed overlap NOK S
Insert)]
committee
Merkmal (Characteristic): <S> Positionierung Nahtlage/Silikonspur
[Prozeß KAB Midfill (Silicone 7 positioning seam position / si- S
Insert)] licone line NOK
committee
Merkmal (Characteristic): Silikondicke
[Prozeß KAB Midfill (Silicone 5 silicon thickness NOK
Insert)]
Merkmal (Characteristic): Silikonbreite
[Prozeß KAB Midfill (Silicone 7 silicone width NOK
Insert)]
committee
Merkmal (Characteristic): <S> keine Fremskörper im Luftsack
[Prozeß KAB Midfill (Silicone 7 no foreign particle in the air- S
Insert)] bag
committee
Merkmal (Characteristic): <S> keine Beschichtung-/Gewebefehler
[Prozeß KAB Midfill (Silicone 7 no coating-/Textile failure S
Insert)]
committee
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] incorrectly scanned AA developing and imple- 2 keine 10 (100) QM IAU / IAU, QM IAU / IAT;
unnecessary prolongation of menting in practice QM, QM IAT / IAU;
the cycle time / lead time TE2 Wien, TE2 Wien
QM, QM IAT / IAU
BMG Freigabe
employee qualifications:
to make sure that exclusively
error allocation in the sy-
stem
TE2 Wien, TE2 Wien
visual error marker for
post-audit
Insert)] cord of test reports bogus process and product specifications: adoption 2 validation of software com- 2 (28) Gottschalk, Markus, TX1;
identification is not possible parameters, as well as well and adaptation / adaptation ponents state-of-the-art tech- Massinger, Jörgen Michael,
of the airbag and / or of com- as standard information / ope- of proven series HW and nology IT;
ponents rational data ( eg , compo- SW componets (for examble QM IAU / IAU, QM IAU / IAT
nent identification data , da- Massinger, Jörgen Michael, IT
[Prozeß KAB Midfill (Silicone 7 AU 316) BMG Freigabe
Insert)] te, time , identity operator mo- implementation of machi-
dule number ) visualize and Gottschalk, Markus, TX1 unbearbeitet (untouched)
process stop with n.i.O. cha- ne acceptance results / main-
racterization (part blocked) store PASS system after relea- tenance plan
se of the validated algo- QM IAU / IAU, QM IAU / IAT
rithms safed against changes
Systemelement (System element): DSS Inspection
Merkmal (Characteristic): <S> Abstand Naht / Silikon
[Prozeß KAB Midfill (Silicone 7 distance seam to silicone S
Insert)] IO
committee
Merkmal (Characteristic): <S> Stichdichte an definierten Punkten (in Handnähte)
[Prozeß KAB Midfill (Silicone 7 stitch density at defined S
Insert)] points (hand stitching) NOK
committee
Merkmal (Characteristic): <S> Position Tether
[Prozeß KAB Midfill (Silicone 7 position Tether NOK S
Insert)]
committee
Merkmal (Characteristic): <S> Position Straps
[Prozeß KAB Midfill (Silicone 7 position Straps NOK S
Insert)]
committee
Merkmal (Characteristic): <S> Position Kreisnähte
[Prozeß KAB Midfill (Silicone 7 position circle seams NIO S
Insert)]
committee
Merkmal (Characteristic): <S> Nahtkreuzungspunke
[Prozeß KAB Midfill (Silicone 7 sewed intersection points S
Insert)] NOK
committee
Merkmal (Characteristic): <S> Complete Seam
[Prozeß KAB Midfill (Silicone 5 Complete Seam NOK (stitch S
Insert)] density IO, thread damage =
unnecessary prolongation of 0, error stitch = 0)
Merkmal (Characteristic): <S> Position Doppelkreisnähte (nicht relevant keine vorhanden)
[Prozeß KAB Midfill (Silicone 7 position double circle se- S
Insert)] ams NOK
committee
[Prozeß KAB Midfill (Silicone 6 false identity Cushion F [Device] Maßnahmenstand - Anfang (Initial state): 31.01.2013
Insert)] do not check defined parame- specifications : DSS fea- 2 implementation of machi- 2 (28) Gottschalk, Markus, TX1;
identification is not possible ters of the cushion ture inspection ne acceptance results / main- QM IAU / IAU, QM IAU / IAT;
of the airbag and / or of com- tenance plan TE2 Wien, TE2 Wien
ponents Gottschalk, Markus, TX1
[Prozeß KAB Midfill (Silicone 6 specifications : image vi-
Insert)] sualization detection through visualiza-
identification of the airbag Gottschalk, Markus, TX1 tion with the device accor-
and / or components only to ding to AA
a limited extent QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 7 sensor scan in the further
Insert)] process
TE2 Wien, TE2 Wien
Merkmal (Characteristic): <F> Position des Label Cushion
[Prozeß KAB Midfill (Silicone 5 position of the label Cushi- F [Device] Maßnahmenstand - Anfang (Initial state): 31.01.2013
Insert)] on NOK do not check defined parame- specifications : DSS fea- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
process stop (only losing ti- ters of the cushion ture inspection ne acceptance results / main- QM IAU / IAU, QM IAU / IAT;
me , no rework the product tenance plan TE2 Wien, TE2 Wien
necessary) Gottschalk, Markus, TX1
[Prozeß KAB Midfill (Silicone 5 specifications : image vi-
Insert)] sualization detection through visualiza-
unnecessary prolongation of Gottschalk, Markus, TX1 tion with the device accor-
the cycle time / lead time ding to AA
sensor scan in the further
process
TE2 Wien, TE2 Wien
Insert)] cord of test reports bogus process and product specifications: adoption 2 validation of software com- 2 (28) Gottschalk, Markus, TX1;
identification is not possible parameters, as well as well and adaptation / adaptation ponents state-of-the-art tech- Massinger, Jörgen Michael,
of the airbag and / or of com- as standard information / ope- of proven series HW and nology IT;
ponents rational data ( eg , compo- SW componets (for examble QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 6 AU 316) BMG Freigabe
Insert)] te, time , identity operator mo- implementation of machi-
identification of the airbag ne acceptance results / main-
and / or components only to store PASS system after relea- tenance plan
a limited extent se of the validated algo- QM IAU / IAU, QM IAU / IAT
Insert)] Cushion position error specifications: mechani- 2 implementation of machi- 2 (24) Gottschalk, Markus, TX1;
process stop (only losing ti- cal positioning ne acceptance results / main- QM IAU / IAU, QM IAU / IAT;
me , no rework the product tenance plan QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 6 employee qualifications:
Insert)] to make sure that exclusively
process stop (rework on pro- and demonstrably trained per-
duct possible / required) sonnel this process step im-
unnecessary prolongation of AA developing and imple-
the cycle time / lead time menting in practice
QM, QM IAT / IAU
wrong decision employee qualifications: 3 sensor scan in the further 2 (36) QM IAU / IAU, QM IAU / IAT;
to make sure that exclusively process QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
AA developing and imple-
menting in practice
QM, QM IAT / IAU
put wrong employee qualifications: 3 sensor scan in the further 2 (36) QM IAU / IAU, QM IAU / IAT;
to make sure that exclusively process QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
menting in practice
QM, QM IAT / IAU
generate false label specifications: adoption and 2 validation of software com- 2 (24) Gottschalk, Markus, TX1;
implementation of machi-
PASS system after release ne acceptance results / main-
of the validated algorithms sa- tenance plan
make wrong use of decision specifications: adoption and 2 validation of software com- 2 (24) Gottschalk, Markus, TX1;
PASS system after release ne acceptance results / main-
of the validated algorithms sa- tenance plan
bogus process and product specifications: adoption 2 validation of software com- 2 (24) Gottschalk, Markus, TX1;
parameters, as well as well and adaptation / adaptation ponents state-of-the-art tech- Massinger, Jörgen Michael,
as standard information / ope- of proven series HW and nology IT;
rational data ( eg , compo- SW componets (for examble QM IAU / IAU, QM IAU / IAT
AU 316) BMG Freigabe
te, time , identity operator mo- implementation of machi-
ne acceptance results / main-
store PASS system after relea- tenance plan
do not check defined parame- specifications : DSS fea- 2 implementation of machi- 2 (24) Gottschalk, Markus, TX1;
ters of the cushion ture inspection ne acceptance results / main- QM IAU / IAU, QM IAU / IAT;
tenance plan TE2 Wien, TE2 Wien
specifications : image vi-
sualization detection through visualiza-
Gottschalk, Markus, TX1 tion with the device accor-
ding to AA
sensor scan in the further
process
TE2 Wien, TE2 Wien
Systemelement (System element): Folding
Merkmal (Characteristic): <S> definierte Faltung durchgeführt
[Prozeß KAB Midfill (Silicone 10 folding NOK S [Device] Maßnahmenstand - Anfang (Initial state): 08.01.2013
Insert)] position of cushion faulty specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigger ve solution for positioning cus- acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
not ( LAH.DUM.880.BF ) hion nance plan QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)] unbearbeitet (untouched)
Airbag inflates when trigge- specifications: sensor control plan: periodic sen-
ring undefined ( LAH.DUM. scanning sor check
880.BF , use safety ) Gottschalk, Markus, TX1 QM, QM IAT / IAU
Insert)] tion
Default deployment direction
DUM.880.BF , use safety) [Device] Maßnahmenstand - Anfang (Initial state): 08.01.2013
Cushion is held incorrectly specifications: a constructi- 2 implementation of machi- 2 (40) Gottschalk, Markus, TX1;
when furling on voltage ve solution for positioning c-pi- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
Insert)]
seek time is too long (LAH. pe (teal help) tenance plan BMG Freigabe
DUM.880.BF) Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
[Prozeß KAB Midfill (Silicone 10 [Device] Maßnahmenstand - Anfang (Initial state): 08.01.2013
Insert)] not fixed cushion in folding pi-
inflation too long ( LAH.DUM. specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
pe ve solution for positioning c-pi- acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
880.BF )
pe (teal help) nance plan QM, QM IAT / IAU
Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)]
separating parts are genera- specifications: sensor control plan: periodic sen-
ted upon deployment (LAH. scanning sor check
DUM.880.BF) Gottschalk, Markus, TX1 QM, QM IAT / IAU
Insert)] tion
process stop (rework on pro-
duct possible / required) QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 7 [Device] Maßnahmenstand - Anfang (Initial state): 08.01.2013
Insert)] folding over on a non defined specifications: a constructi- 3 implementation of machi- 3 (90) Gottschalk, Markus, TX1;
committee dimensional measurment (on- ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
ly 3 - heron) sign (flip-over / fixing flip- tenance plan
Insert)] over) QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
unnecessary prolongation of Gottschalk, Markus, TX1
the cycle time / lead time Maßnahmenstand (Revision state): 08.01.2013
[Prozeß KAB Midfill (Silicone 10 3 implementation of machi- 3 (90) QM IAU / IAU, QM IAU / IAT;
Insert)] ne acceptance results / main- QM, QM IAT / IAU;
process stop at the custo- tenance plan TE2 Wien, TE2 Wien
mer (return required)
Insert)] sensor scan for sample po-
identification is not possible sitioning
ponents
control plan: periodic sen-
[Prozeß KAB Midfill (Silicone 6 sor check
Insert)]
QM, QM IAT / IAU
and / or components only to control plan: 100% inspec-
a limited extent tion
Insert)] [Technican] Maßnahmenstand - Anfang (Initial state): 04.07.2013
identification of the airbag faulty program selection
and / or components only plausiblity test of the system 2 check in PASS system 2 (40) Massinger, Jörgen Michael, IT
with increased effor while scanning the airbag BMG Freigabe
process upset - no further pro- undefined position of the AA developing and implemen- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
cessing possible start point ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 7 nance plan QM, QM IAT / IAU
QM, QM IAT / IAU
Insert)] QM IAU / IAU, QM IAU / IAT BMG Freigabe
process stop with n.i.O. cha- specifications: sensor
racterization (part blocked) scanning control plan: 100% inspec-
Gottschalk, Markus, TX1 tion
sor test with test pieces
QM, QM IAT / IAU
adjust the starting point of 1 keine 1 (10) TE2 Wien, TE2 Wien
the convolution for defined BMG Freigabe
projects unbearbeitet (untouched)
undefined position endpoint AA developing and implemen- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
QM, QM IAT / IAU
scanning control plan: 100% inspec-
QM, QM IAT / IAU
Merkmal (Characteristic): Cushion IO
[Prozeß KAB Midfill (Silicone 10 damaged Cushion [Operator] Maßnahmenstand - Anfang (Initial state): 29.11.2012
Insert)] damaged during removal employee qualifications: 2 implementation of machi- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- to make sure that exclusively ne acceptance results / main- QM, QM IAT / IAU
ring undefined ( LAH.DUM. and demonstrably trained per- tenance plan
is not complied with (LAH. AA developing and imple-
DUM.880.BF , use safety) menting in practice
[Prozeß KAB Midfill (Silicone 10 QM, QM IAT / IAU
seek time is too long (LAH. faulty program selection plausiblity test of the system 2 check in PASS system 2 (40) Massinger, Jörgen Michael, IT
DUM.880.BF)
while scanning the airbag BMG Freigabe
Insert)]
inflation too long ( LAH.DUM. [Device] Maßnahmenstand - Anfang (Initial state): 20.01.2014
880.BF ) airbag is damaged during specifications : suitable de- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
the buckling of the C -pipe of sign of the tail of the buckling acceptance results / mainte- QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 10 backstop
Insert)] sword ( sharp edges) nance plan BMG Freigabe
life too short (LAH.DUM.880. Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
BF)
[Prozeß KAB Midfill (Silicone 10 ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
Insert)] damaged Cushion [Device] Gottschalk, Markus, TX1 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
filling gas flows directly into airbag is damaged during unbearbeitet (untouched)
vehicle interior the buckling of the C -pipe of
[Prozeß KAB Midfill (Silicone 10 backstop
Insert)]
DUM.880.BF)
Insert)]
committee
Insert)] cord of test reports bogus process and product specifications: adoption and 2 plausibility check of data 2 (32) Gottschalk, Markus, TX1;
identification is not possible parameters, as well as well adaptation / adaptation of pro- Massinger, Jörgen Michael,
of the airbag and / or of com- as standard information / ope- Massinger, Jörgen Michael, IT
ponents rational data ( eg , compo- ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 8 nent identification data , da- results
te, time , identity operator mo- Gottschalk, Markus, TX1 BMG Freigabe
identification of the airbag dule number ) visualize and PASS system after release
and / or components wrong store of the validated algorithms sa-
fed against changes
process stop with n.i.O. cha- [Technican] Maßnahmenstand - Anfang (Initial state): 04.07.2013
racterization (part blocked) faulty program selection plausiblity test of the system 2 check in PASS system 2 (32) Massinger, Jörgen Michael, IT
Insert)] does not boot kink- help specifications: sensor 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
process stop (only losing ti- scanning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
me , no rework the product nance plan QM, QM IAT / IAU
Insert)] make sure that exclusively control plan: periodic sen-
process upset - no further pro- and demonstrably trained per- sor check
cessing possible sonnel this process step im- QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
positioned C -pipe not in devi- employee qualifications: to 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
ce make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
and demonstrably trained per- nance plan QM, QM IAT / IAU
QM IAU / IAU, QM IAU / IAT sor check
AA developing and implemen- QM, QM IAT / IAU
ting in practice
specifications: sensor QM IAU / IAU, QM IAU / IAT
scanning
does not move along the in- specifications: sensor 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
sert guides scanning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
make sure that exclusively control plan: periodic sen-
and demonstrably trained per- sor check
ting in practice
QM, QM IAT / IAU
does not move folding pipe specifications: sensor 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
in basic position scanning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
QM, QM IAT / IAU
do not record in the folding pi- specifications: sensor 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
pe scanning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
sor check
QM, QM IAT / IAU
tion
erroneous recording of the C specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
-pipe ve solution for fixing aid ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
Gottschalk, Markus, TX1 tenance plan BMG Freigabe
no fixing (by retainer) of the specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
rolled Cushion ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
sign tenance plan BMG Freigabe
Gottschalk, Markus, TX1 QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
^ ^ ^ ^ ^ [Device] Maßnahmenstand - Anfang (Initial state): 08.01.2013
[Prozeß KAB Midfill (Silicone 4 faulty process / interruptions no extension of the folding pi- specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
Insert)] pe ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
process upset - no further pro- sign tenance plan
cessing possible BMG Freigabe
hold-down drive down fol- specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
ding pipe not go out ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
sign tenance plan BMG Freigabe
does not add the rolled Cushi- specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
on by buckling in C- pipe ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
sign (flip-over / fixing flip- tenance plan BMG Freigabe
over) QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
does not move in the basic specifications: a constructi- 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
position for removal of the ve account of the system de- ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
Folded Cushion in C- pipe sign (flip-over / fixing flip- tenance plan BMG Freigabe
over) QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
[C- Pipe] Maßnahmenstand - Anfang (Initial state): 08.01.2013
faulty hold / no provision of technical specifications: a 2 implementation of machi- 2 (20) Gottschalk, Markus, TX1;
the Folded Cushion constructive consideration of ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
the auxiliary tool tenance plan BMG Freigabe
[Tracebility system]
make wrong use of decision
generate false label specifications: adoption and 2 plausibility check of data 2 (20) Gottschalk, Markus, TX1;
adaptation / adaptation of pro- Massinger, Jörgen Michael,
results
fed against changes
specify steps wrong specifications: adoption and 2 plausibility check of data 2 (20) Gottschalk, Markus, TX1;
results
fed against changes
bogus process and product specifications: adoption and 2 plausibility check of data 2 (20) Gottschalk, Markus, TX1;
parameters, as well as well adaptation / adaptation of pro- Massinger, Jörgen Michael,
as standard information / ope- Massinger, Jörgen Michael, IT
rational data ( eg , compo- ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
nent identification data , da- results
dule number ) visualize and PASS system after release
store of the validated algorithms sa-
fed against changes
specify steps wrong specifications: adoption 2 validation of software com- 2 (20) Gottschalk, Markus, TX1;
and adaptation / adaptation ponents state-of-the-art tech- Massinger, Jörgen Michael,
of proven series HW and nology IT;
SW componets (for examble QM IAU / IAU, QM IAU / IAT
AU 316) BMG Freigabe
Gottschalk, Markus, TX1 unbearbeitet (untouched)
ne acceptance results / main-
PASS system after relea- tenance plan
faulty program selection plausiblity test of the system 2 check in PASS system 2 (20) Massinger, Jörgen Michael, IT
erroneous position/ type AA developing and implemen- 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
strap hook ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
QM, QM IAT / IAU
[Technican]
incorrect insertion
undefined position endpoint AA developing and implemen- 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
QM, QM IAT / IAU
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 8 false identity Cushion F [Operator]
Insert)] do not scan cushion label
identification of the airbag (not relevant)
Insert)]
Systemelement (System element): Cover Assembly
Merkmal (Characteristic): <S> Positionierung Cover zu Cushion Folded (roter / schwarzer Balken)
[Prozeß KAB Midfill (Silicone 10 positioning Cushion Folded S [Operator] Maßnahmenstand - Anfang (Initial state): 30.01.2013
Insert)] Cover to faulty position / clamp with cover in- employee qualifications: to 9 implementation of machine 9 (810) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- sertion in Device faulty make sure that exclusively acceptance results / mainte- QM, QM IAT / IAU
ring undefined ( LAH.DUM. and demonstrably trained per- nance plan
is not complied with (LAH. AA developing and implemen-
DUM.880.BF , use safety) ting in practice
Insert)] Maßnahmenstand (Revision state): 30.01.2013
specifications: sensor 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
scanning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
DUM.880.BF) QM, QM IAT / IAU
specifications :mechani- QM IAU / IAU, QM IAU / IAT
given space in the vehicle is cal positioning insertion control plan: periodic sen-
exceeded (Package) (LAH. Gottschalk, Markus, TX1 sor check
DUM.880.BF) QM, QM IAT / IAU
specifications: cover at-
[Prozeß KAB Midfill (Silicone 10 tachment to the insertion control plan: 100% inspec-
Insert)] tion
impairment of surrounding ve- Gottschalk, Markus, TX1
hicle components possible specifications: positioning QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 10 helper of the insertion in devi-

Insert)] ce
installation in the vehicle in- Gottschalk, Markus, TX1
correctly possible (not visible employee qualifications: to
) ( LAH.DUM.880.BF ) make sure that exclusively
[Prozeß KAB Midfill (Silicone 6 and demonstrably trained per-
Insert)] sonnel this process step im-
process stop (rework on pro- plemented (quality matrix)
duct possible / required) QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 7 AA developing and implemen-
Insert)] ting in practice
committee
QM, QM IAT / IAU
Insert)] [Operator] Maßnahmenstand - Anfang (Initial state): 30.01.2013
unnecessary prolongation of adds Cushion Folded erro- employee qualifications: to 9 implementation of machine 9 (810) QM IAU / IAU, QM IAU / IAT;
the cycle time / lead time neous ( in the C- Pipe) in Co- make sure that exclusively acceptance results / mainte- QM, QM IAT / IAU
ver + insertion and demonstrably trained per- nance plan BMG Freigabe
ting in practice
QM, QM IAT / IAU
specifications: sensor ori- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
entation scanning with c -pipe acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
QM, QM IAT / IAU
Cover not fixierenund Cushi- employee qualifications: 3 detection in executing of 2 (60) QM IAU / IAU, QM IAU / IAT;
on folded in Device lock to make sure that exclusively strap according to AA QM, QM IAT / IAU
plemented (quality matrix) visual inspection in sub
process "clip assembly" accor-
QM IAU / IAU, QM IAU / IAT ding AA
AA developing and imple- QM IAU / IAU, QM IAU / IAT
menting in practice
QM, QM IAT / IAU
Merkmal (Characteristic): Cushion Folded Form geben
[Prozeß KAB Midfill (Silicone 10 give Cushion Folded defecti- [Operator] Maßnahmenstand - Anfang (Initial state): 30.01.2013
Insert)] ve form adds Cushion Folded erro- employee qualifications: to 9 implementation of machine 9 (810) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- neous ( in the C- Pipe) in Co- make sure that exclusively acceptance results / mainte- QM, QM IAT / IAU
ring undefined ( LAH.DUM. ver + insertion and demonstrably trained per- nance plan
is not complied with (LAH. AA developing and implemen-
Insert)] Maßnahmenstand (Revision state): 30.01.2013
specifications: sensor ori- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
vehicle interior
entation scanning with c -pipe acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 nance plan QM, QM IAT / IAU
employee qualifications: to QM IAU / IAU, QM IAU / IAT
separating parts are genera- unbearbeitet (untouched)
ted upon deployment (LAH. make sure that exclusively control plan: periodic sen-
DUM.880.BF) and demonstrably trained per- sor check
Insert)] control plan: 100% inspec-
given space in the vehicle is QM IAU / IAU, QM IAU / IAT tion
exceeded (Package) (LAH. AA developing and implemen-
ting in practice
Insert)]
impairment of surrounding ve- [Operator] Maßnahmenstand - Anfang (Initial state): 30.01.2013
hicle components possible Cover not fixierenund Cushi-
on folded in Device lock
[...] ^[...] ^ ^ ^ ^ ^ employee qualifications: 3 detection in executing of 2 (60) QM IAU / IAU, QM IAU / IAT;
give Cushion Folded defecti- [Operator] to make sure that exclusively strap according to AA QM, QM IAT / IAU
ve form Cover not fixierenund Cushi- and demonstrably trained per- QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)]
on folded in Device lock sonnel this process step im- unbearbeitet (untouched)
process stop (only losing ti- visual inspection in sub
me , no rework the product process "clip assembly" accor-
necessary) QM IAU / IAU, QM IAU / IAT ding AA
[Prozeß KAB Midfill (Silicone 7 AA developing and imple- QM IAU / IAU, QM IAU / IAT
Insert)] menting in practice
committee QM, QM IAT / IAU
Insert)]
and / or components only store of the validated algorithms sa-
with increased effor fed against changes
Insert)]
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Tracebility system] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] make wrong use of decision specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
process stop (only losing ti- adaptation / adaptation of pro- Massinger, Jörgen Michael,
me , no rework the product Massinger, Jörgen Michael, IT
necessary) ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
committee PASS system after release
fed against changes
results
fed against changes
results
fed against changes
fed against changes
[Cover] Maßnahmenstand - Anfang (Initial state): 20.09.2012
not met the standards speci- specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
fied drawing UPS with delivered parts QM, QM IAT / IAU
not execute attachment employee qualifications: 3 visual inspection in sub 2 (42) QM IAU / IAU, QM IAU / IAT;
strap of the Cushion Folded to make sure that exclusively process "clip assembly" accor- QM, QM IAT / IAU
and demonstrably trained per- ding AA BMG Freigabe
menting in practice
QM, QM IAT / IAU
[C-Pipe] Maßnahmenstand - Anfang (Initial state): 08.01.2013
faulty hold / no provision of technical specifications: a 2 implementation of machi- 2 (28) Gottschalk, Markus, TX1;
the Folded Cushion constructive consideration of ne acceptance results / main- QM IAU / IAU, QM IAU / IAT
the auxiliary tool tenance plan BMG Freigabe
Merkmal (Characteristic): <F> Identität Cover
[Prozeß KAB Midfill (Silicone 6 false / no identity Cover F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] not observed end of charge AA developing and imple- 2 control plan: 100% inspec- 4 (48) Fiedler, Jens, TE2 IAB;
identification of the airbag menting in practice tion Gottschalk, Markus, TX1;
and / or components only to QM IAU / IAU, QM IAU / IAT;
a limited extent QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
[Prozeß KAB Midfill (Silicone 5 ergonomic workplace de- TE2 Wien, TE2 Wien
Insert)] sign
BMG Freigabe
identification of the airbag TE2 Wien, TE2 Wien unbearbeitet (untouched)
specifications: visual dis-
play of the batch progress
fixed define batches
Fiedler, Jens, TE2 IAB
Systemelement (System element): Metal Detection
Merkmal (Characteristic): <S> Detektion
[Prozeß KAB Midfill (Silicone 10 detection NOK S [Device] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] misdetection maintenance plan 2 control plan: define periodic 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- measurement system verifica- TE2 Wien, TE2 Wien
tion (by mistake provocation) BMG Freigabe
880.BF , use safety ) and ensure result record unbearbeitet (untouched)
Insert)]
DUM.880.BF , use safety)
Insert)]
DUM.880.BF)
Insert)]
880.BF )
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
[Prozeß KAB Midfill (Silicone 10 not performed detection [Operator] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] not equip the device AA developing and imple- 5 10 (500) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- menting in practice QM, QM IAT / IAU;
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 employee qualifications:
Insert)] to make sure that exclusively
Default deployment direction and demonstrably trained per-
Insert)] ergonomic workplace de-
seek time is too long (LAH. sign
DUM.880.BF)
TE2 Wien, TE2 Wien
Insert)]
880.BF )
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
[Prozeß KAB Midfill (Silicone 7 faulty process / interruptions [Metal Body] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] presence specifications: define work- 2 sensor check in process 2 (28) Gottschalk, Markus, TX1;
committee place equipment / design for TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
each process step BMG Freigabe
Gottschalk, Markus, TX1 unbearbeitet (untouched)
Systemelement (System element): Package Holder Assembly
Merkmal (Characteristic): <F> Vorhandensein aller Clips mit Package Supports
[Prozeß KAB Midfill (Silicone 8 Clip not available F [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] no / incorrect assembly of all AA developing and implemen- 4 check position and presence 2 (64) QM IAU / IAU, QM IAU / IAT;
installation in the vehicle the clips with Package Sup- ting in practice in process step "clip QM, QM IAT / IAU
is not possible ( visible ) ( port / spacer (only VW 378) checking" with camera sen-
LAH.DUM.880.BF ) QM, QM IAT / IAU BMG Freigabe
sor unbearbeitet (untouched)
make sure that exclusively QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 10 package support not availa- F [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] ble no / incorrect assembly of all AA developing and implemen- 4 check position and presence 2 (80) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- the clips with Package Sup- ting in practice in process step "clip QM, QM IAT / IAU
ring undefined ( LAH.DUM. port / spacer (only VW 378) checking" with camera sen-
Insert)]
installation in the vehicle and demonstrably trained per-
is not possible ( visible ) ( sonnel this process step im-
LAH.DUM.880.BF ) plemented (quality matrix)
[Prozeß KAB Midfill (Silicone 10 attachment strap not in the F [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] correct position no / incorrect assembly of all AA developing and implemen- 4 check position and presence 2 (80) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- the clips with Package Sup- ting in practice in process step "clip QM, QM IAT / IAU
ring undefined ( LAH.DUM. port / spacer (only VW 378) checking" with camera sen-
Merkmal (Characteristic): <F> Vorhandensein Spacer (nur VW 378)
[Prozeß KAB Midfill (Silicone 10 availability of the spacer (on- F [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] ly VW 378) NOK no / incorrect assembly of all AA developing and implemen- 4 check position and presence 2 (80) QM IAU / IAU, QM IAU / IAT;
seek time is too long (LAH. the clips with Package Sup- ting in practice in process step "clip QM, QM IAT / IAU
DUM.880.BF) port / spacer (only VW 378) checking" with camera sen-
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Package Support] Maßnahmenstand - Anfang (Initial state): 20.09.2012
process stop (only losing ti- fied drawing UPS with delivered parts QM, QM IAT / IAU
me , no rework the product
Insert)] [Metal Clip] Maßnahmenstand - Anfang (Initial state): 20.09.2012
committee not met the standards speci- specific guidelines on TLV / 2 incoming goods inspection 4 (56) QM, QM IAA;
[Label Cushion Folded] Maßnahmenstand - Anfang (Initial state): 20.09.2012
fed against changes
Insert)]
Merkmal (Characteristic): <F> Identität Clip
[Prozeß KAB Midfill (Silicone 8 false / no identity clip F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] not observed end of charge AA developing and implemen- 2 control plan: 100% inspec- 4 (64) Fiedler, Jens, TE2 IAB;
identification of the airbag ting in practice tion Gottschalk, Markus, TX1;
and / or components wrong QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
ergonomic workplace design TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien BMG Freigabe
specifications: visual dis- unbearbeitet (untouched)
Merkmal (Characteristic): <F> Identität Package Support
[Prozeß KAB Midfill (Silicone 8 false / no identity Package F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] Support not observed end of charge AA developing and implemen- 2 control plan: 100% inspec- 4 (64) Fiedler, Jens, TE2 IAB;
identification of the airbag ting in practice tion Gottschalk, Markus, TX1;
and / or components wrong QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
ergonomic workplace design TE2 Wien, TE2 Wien
specifications: visual dis- unbearbeitet (untouched)
Systemelement (System element): Metal Hook Sewing
[Prozeß KAB Midfill (Silicone 10 positionof seam NOK S [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] sorik)] maintenance plan 3 process monitoring by opera- 2 (60) Gottschalk, Markus, TX1;
Airbag inflates when trigge- thread run NOK tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
880.BF , use safety ) specification: process monito- QM IAU / IAU, QM IAU / IAT
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 ring by machine / software
BF)
[Prozeß KAB Midfill (Silicone 10 stopped sewing ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU ding to AA
vehicle interior QM IAU / IAU, QM IAU / IAT BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 make sure that exclusively
Insert)] and demonstrably trained per-
committee sonnel this process step im-
unnecessary prolongation of specification: process mo-
the cycle time / lead time nitoring by machine / soft-
ware
Merkmal (Characteristic): <S> Position optionaler Bauteile
[Prozeß KAB Midfill (Silicone 10 incorrect position of optional S [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] components positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. ponents faulty TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
seek time is too long (LAH. Gottschalk, Markus, TX1 nance plan
Insert)]
880.BF )
Insert)] incorrect position of optional [Tooling] Gottschalk, Markus, TX1 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
life too short (LAH.DUM.880. components positioning and fixing airbag unbearbeitet (untouched)
BF) and optional further com-
[Prozeß KAB Midfill (Silicone 10 ponents faulty
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
Insert)]
committee
Merkmal (Characteristic): <S> Vollständigkeit optionaler Bauteile
[Prozeß KAB Midfill (Silicone 10 incompleteness optional com- S [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] ponents sorik)] maintenance plan 3 process monitoring by ope- 2 (60) Gottschalk, Markus, TX1;
Airbag inflates when trigge- optionally: not check the pre- rator according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. sence and the sequence of TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
880.BF , use safety ) the air bag, and optionally fur- specifications: sensor QM IAU / IAU, QM IAU / IAT
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 ther components scanning control plan: periodic sen-
BMG Freigabe
Insert)] Gottschalk, Markus, TX1 sor test with test pieces
seek time is too long (LAH. QM, QM IAT / IAU
specification: process monito-
DUM.880.BF)
Insert)]
inflation too long ( LAH.DUM. periodic errors provocation
880.BF ) QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 10 [Operator] Maßnahmenstand - Anfang (Initial state): 14.10.2013
Insert)] no / incorrect assembly bolt
life too short (LAH.DUM.880. AA developing and implemen- 2 control plan: 100% inspec- 2 (40) Gottschalk, Markus, TX1;
through Metal Hook in ting in practice tion QM IAU / IAU, QM IAU / IAT;
BF) Spring Nut QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
Insert)] employee qualifications: to control plan: periodic sen-
filling gas flows directly into make sure that exclusively sor test with test pieces
vehicle interior and demonstrably trained per- QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 sonnel this process step im-
committee QM IAU / IAU, QM IAU / IAT
specifications: installation of
screw help Audi in production
scanning with in the process
step "clip checking" on came-
ra sensor
Merkmal (Characteristic): <S> CNC Sewing Machine mit Threads bestücken
TE2 Wien, TE2 Wien
process stop with n.i.O. cha- plemented (quality matrix) machine downtime in the
racterization (part blocked) next part process
Insert)] ting in practice control plan: 100% visual in-
process upset - no further pro- spection in the sub-process
cessing possible QM, QM IAT / IAU "Light Table"
sorik)] maintenance plan 3 process monitoring by opera- 2 (42) QM IAU / IAU, QM IAU / IAT;
not guarantee delivery tor according to AA TE2 Wien, TE2 Wien
threads TE2 Wien, TE2 Wien
(bobbin thread monitor
thread)
Insert)] thread and / or incorrect need- wrong selection of bobbin / AA developing and implemen- 2 control plan: visual examinati- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigger le thread neddle thread ting in practice on at the beginning of the QM, QM IAT / IAU
not ( LAH.DUM.880.BF ) next part of the process
[Prozeß KAB Midfill (Silicone 10 QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
Insert)] employee qualifications: to
Airbag inflates when trigge- make sure that exclusively control plan: 100% visual in-
ring undefined ( LAH.DUM. and demonstrably trained per- spection in the sub-process
880.BF , use safety ) sonnel this process step im- "Light Table"
seek time is too long (LAH. [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
DUM.880.BF) not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
Insert)] and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
inflation too long ( LAH.DUM. sonnel this process step im- BMG Freigabe
880.BF ) plemented (quality matrix) machine downtime in the
next part process
Insert)] TE2 Wien, TE2 Wien
life too short (LAH.DUM.880. control plan: 100% visual in-
ting in practice
BF) spection in the sub-process
vehicle interior
Insert)]
DUM.880.BF)
Merkmal (Characteristic): <S> Cushion und optional weitere Bauteile in CNC Sewing Machine IO
[Prozeß KAB Midfill (Silicone 10 inserted Cushion and / or op- S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] tionally other components in positioned air bag and AA developing and implemen- 2 specifications issue: sen- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- wrong order other optional components is ting in practice sor query location detection QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. incorrect / (sewing clamp) QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BF) sonnel this process step im-
^ ^ ^ ^ ^S ^ ^ ^ ^ ^ ^ BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 inserted Cushion and / or op- [Operator] employee qualifications: to 2 TE2 Wien, TE2 Wien 2 (40) unbearbeitet (untouched)
[...] tionally other components in positioned air bag and make sure that exclusively control plan: 100% inspec-
wrong order other optional components is [...] tion
[Prozeß KAB Midfill (Silicone 10 incorrect / (sewing clamp)
Insert)]
Insert)]
Insert)] AA developing and implemen-
unnecessary prolongation of ting in practice control plan: 100% visual in-
the cycle time / lead time spection in the sub-process
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
inserted incorrect optional
components (not relevant)
[Prozeß KAB Midfill (Silicone 10 optional additional com- S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ponents not loaded complete positioned air bag and AA developing and implemen- 2 specifications issue: sen- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- other optional components is ting in practice sor query location detection QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. incorrect / (sewing clamp) QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
BF)
Insert)]
Insert)]
process stop (only losing ti- next part process
me , no rework the product QM IAU / IAU, QM IAU / IAT
committee
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 Cushion is not in the correct S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] position loaded into CNC Se- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- wing Machine and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
positioned air bag and AA developing and implemen- 2 specifications issue: sen- 2 (40) Gottschalk, Markus, TX1;
other optional components is ting in practice sor query location detection QM IAU / IAU, QM IAU / IAT;
incorrect / (sewing clamp) QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
not observed process acces-
sible handling
^ ^ ^ ^ ^S ^ ^ employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 7 Cushion is not in the correct [Operator] make sure that exclusively rent subprocess QM, QM IAT / IAU;
Insert)] position loaded into CNC Se- not observed process acces- and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
committee wing Machine sible handling sonnel this process step im- BMG Freigabe
next part process
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 optional additional com- S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] ponents not installed in the does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- correct position and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
committee Gottschalk, Markus, TX1 nance plan
Insert)] [Tooling] Maßnahmenstand - Anfang (Initial state): 26.09.2012
life too short (LAH.DUM.880. positioning and fixing airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
BF) and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ponents faulty TE2 Wien, TE2 Wien
filling gas flows directly into constructive account of the implementation of machine
vehicle interior design tool acceptance results / mainte-
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
Merkmal (Characteristic): <S> Cushion und optional weitere Bauteile mittels CNC Sewing Machine vernähen
[Prozeß KAB Midfill (Silicone 10 Cushion and optional further S [Technican] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] components with a false se- Incorrect setting of the machi- AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- am sewn ( position air bag ne 2 - herons, 3 - heron ting in practice AA QM, QM IAT / IAU
ring undefined ( LAH.DUM. components seam)
filling gas flows directly into [Sewing Machine (Table, Sen- Maßnahmenstand - Anfang (Initial state): 26.09.2012
vehicle interior sorik)] maintenance plan 2 process monitoring by opera- 3 (60) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 7 not sewn custom sewing tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
Insert)] ding to AA TE2 Wien, TE2 Wien
committee specification: process mo-
ware
[Prozeß KAB Midfill (Silicone 10 sewed Cushion and optional S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] further components not com- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- pletely and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
Incorrect setting of the machi-
ne 2 - herons, 3 - heron
^ ^ ^ ^ ^S ^ ^ AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 7 sewed Cushion and optional [Technican] ting in practice AA QM, QM IAT / IAU
Insert)] further components not com- Incorrect setting of the machi- QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT BMG Freigabe
committee pletely ne 2 - herons, 3 - heron unbearbeitet (untouched)
TE2 Wien, TE2 Wien
plemented (quality matrix) process monitoring by ope-
rator according to AA
ting in practice
QM, QM IAT / IAU
bobbin
not observe yarn length of employee qualifications: to 3 machine downtime in the cur- 3 (90) Gottschalk, Markus, TX1;
the upper thread make sure that exclusively rent subprocess QM IAU / IAU, QM IAU / IAT;
and demonstrably trained per- QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
tor according to AA
ting in practice
QM, QM IAT / IAU
specifications : thread moni-
tor
sorik)] maintenance plan 2 process monitoring by opera- 3 (60) Gottschalk, Markus, TX1;
not sewn custom sewing tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
ding to AA TE2 Wien, TE2 Wien
ware
Cushion and optionally
other components with the
wrong stitch density sutured
( NOT RELEVANT )
[Prozeß KAB Midfill (Silicone 10 Cushion and optionally other S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] components outside of the si- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- licone trace stitched ( only and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. with seams within the silicon ponents TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
880.BF , use safety ) track ) technical specifications: a QM IAU / IAU, QM IAU / IAT
BMG Freigabe
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 Cushion is sutured using S [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] CNC Sewing Machine too clo- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- se to the edge of the silicon and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. track ponents TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^S [Operator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
[Prozeß KAB Midfill (Silicone 7 Cushion is sutured using positioned air bag and AA developing and implemen- 2 specifications issue: sen- 2 (40) Gottschalk, Markus, TX1;
Insert)] CNC Sewing Machine too clo- other optional components is ting in practice sor query location detection QM IAU / IAU, QM IAU / IAT;
committee se to the edge of the silicon incorrect / (sewing clamp) QM, QM IAT / IAU;
track QM, QM IAT / IAU TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
next part process
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 10 sewed cushion and optional [Tooling] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] further components with incor- does not take / faulty airbag maintenance plan 2 process monitoring by opera- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- rect thread tension and optional further com- tor according to AA QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
BMG Freigabe
employee training plan
QM, QM IAT / IAU
maintenance plan
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe
maintenance plan
TE2 Wien, TE2 Wien
wrong selection of bobbin / AA developing and implemen- 2 control plan: visual examinati- 2 (40) QM IAU / IAU, QM IAU / IAT;
neddle thread ting in practice on at the beginning of the QM, QM IAT / IAU
QM, QM IAT / IAU next part of the process BMG Freigabe
make sure that exclusively control plan: 100% visual in-
and demonstrably trained per- spection in the sub-process
sonnel this process step im- "Light Table"
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^ ^ ^ [...] ^ ^ ^ BMG Freigabe
machine downtime in the
[Prozeß KAB Midfill (Silicone 7 sewed cushion and optional [Operator] 3 3 (90) unbearbeitet (untouched)
next part process
Insert)] further components with incor- not observed process acces- QM IAU / IAU, QM IAU / IAT
committee rect thread tension sible handling TE2 Wien, TE2 Wien
QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
sorik)] AA developing and implemen- 2 control plan: 100% visual 2 (40) QM IAU / IAU, QM IAU / IAT;
needle breakage ting in practice inspection QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
QM, QM IAT / IAU
maintenance plan
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

[Prozeß KAB Midfill (Silicone 10 sewed cushion and optional [Technican] Maßnahmenstand - Anfang (Initial state): 05.02.2013
Insert)] further components with skip- not observe defined machine AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- ped stitches settings ting in practice tor according to AA QM, QM IAT / IAU;
BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 employee training plan
maintenance plan
BF)
TE2 Wien, TE2 Wien
Insert)] periodic changing the needle
filling gas flows directly into after maintenance plan
[Prozeß KAB Midfill (Silicone 7 [Operator] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] wrong selection of bobbin /
committee AA developing and implemen- 2 control plan: visual examinati- 2 (40) QM IAU / IAU, QM IAU / IAT;
sorik)] AA developing and implemen- 2 control plan: 100% visual 2 (40) QM IAU / IAU, QM IAU / IAT;
needle breakage ting in practice inspection QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
QM, QM IAT / IAU
maintenance plan
TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

[Prozeß KAB Midfill (Silicone 10 sewed cushion and optional S [Technican] Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] further components with faul- Incorrect setting of the machi- AA developing and implemen- 2 first piece testing/ check by 2 (40) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigge- ty overlap ne 2 - herons, 3 - heron ting in practice AA QM, QM IAT / IAU
vehicle interior needel selection NOK AA developing and implemen- 2 process monitoring by opera- 2 (40) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 7 ting in practice tor according to AA QM, QM IAT / IAU;
Insert)] TE2 Wien, TE2 Wien
committee
^ ^ ^ ^ ^S ^ ^ ^ ^ ^ BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 sewed cushion and optional [Technican] 2 2 (40) unbearbeitet (untouched)
Insert)] further components with faul- needel selection NOK
committee ty overlap maintenance plan QM IAU / IAU, QM IAU / IAT

with drawing

[Prozeß KAB Midfill (Silicone 10 sewed cushion and optional S [Sewing Threads (Bobbin + Maßnahmenstand - Anfang (Initial state): 26.09.2012
Insert)] further components with Needle)] employee training plan 2 thread monitor: when pro- 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- thread breakage thread breakage cess is interrupted QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
BMG Freigabe
life too short (LAH.DUM.880. ting in practice part with declared error NOK
BF)
[Prozeß KAB Midfill (Silicone 10 BMG Freigabe ble?)
Insert)] (unbearbeitet (untouched)) Termin? (Deadline?)
filling gas flows directly into (unbearbeitet (untouched))
vehicle interior specifications : thread moni-
tor
wrong selection of bobbin / AA developing and implemen- 2 control plan: visual examinati- 2 (40) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
BMG Freigabe

with drawing

committee specify steps wrong specifications: adoption and 2 validation of software com- 2 (28) Gottschalk, Markus, TX1;
PASS system after release acceptance results / mainte-
of the validated algorithms sa- nance plan
not performed sewing ting in practice tor / machine / software accor- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
ware
positioning no spring nut in AA developing and implemen- 2 control plan: 100% inspec- 2 (28) Gottschalk, Markus, TX1;
mounting apparatus of the se- ting in practice tion QM IAU / IAU, QM IAU / IAT;
wing machine QM, QM IAT / IAU
BMG Freigabe
employee qualifications: to control plan: periodic sen-
make sure that exclusively sor test with test pieces
specifications: a constructive
solution orientation of spring
nut
ra sensor
[Prozeß KAB Midfill (Silicone 8 disturbed process on tape [Operator] Maßnahmenstand - Anfang (Initial state): 14.10.2013
Insert)] (OEM) positioning metal hook into AA developing and implemen- 2 control plan: 100% inspec- 2 (32) Gottschalk, Markus, TX1;
installation in the vehicle the mounting device incorrect- ting in practice tion QM IAU / IAU, QM IAU / IAT;
is not possible ( visible ) ( ly or not QM, QM IAT / IAU
LAH.DUM.880.BF ) QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
^ ^ ^ ^ ^ ^ ^ specifications: a constructive ^ ^ ^ ^ ^
[Prozeß KAB Midfill (Silicone 8 disturbed process on tape [Operator] solution positioning metal 2 QM, QM IAT / IAU 2 (32) BMG Freigabe
Insert)] (OEM) positioning metal hook into hook unbearbeitet (untouched)
installation in the vehicle the mounting device incorrect- Gottschalk, Markus, TX1
is not possible ( visible ) ( ly or not
LAH.DUM.880.BF ) specifications: sensor
ra sensor
no / incorrect assembly bolt AA developing and implemen- 2 control plan: 100% inspec- 2 (32) Gottschalk, Markus, TX1;
through Metal Hook in ting in practice tion QM IAU / IAU, QM IAU / IAT;
Spring Nut QM, QM IAT / IAU
BMG Freigabe
specifications: installation of
screw help Audi in production
ra sensor
could not recognize the cess lead to faulty adaptation / adaptation of pro- Massinger, Jörgen Michael,
locking state of the Securing Massinger, Jörgen Michael, IT
Unit at assembly ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
identification is not possible PASS system after release
identification of the airbag records results of the pro- specifications: adoption and 2 plausibility check of data 2 (40) Gottschalk, Markus, TX1;
and / or components only to cess cycle defective / not on adaptation / adaptation of pro- Massinger, Jörgen Michael, IT Massinger, Jörgen Michael,
a limited extent IT;
ven series HW and SW com-
Insert)] results
identification of the airbag QM, QM IAT / IAU unbearbeitet (untouched)
and / or components only PASS system after release
with increased effor of the validated algorithms sa-
fed against changes
Merkmal (Characteristic): <F> Identität Bobbin / Neddle Thread
[Prozeß KAB Midfill (Silicone 10 erroneous identity bobbin / F [Operator] Maßnahmenstand - Anfang (Initial state): 21.08.2012
Insert)] neddle thread not observed process acces- employee qualifications: to 3 machine downtime in the cur- 3 (90) QM IAU / IAU, QM IAU / IAT;
inflation too long ( LAH.DUM. sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
identification of the airbag next part process
and / or components only to TE2 Wien, TE2 Wien
a limited extent AA developing and implemen-
process stop (rework on pro- sible handling make sure that exclusively rent subprocess QM, QM IAT / IAU;
duct possible / required) and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
identification is not possible next part process
a limited extent
Insert)]
Merkmal (Characteristic): <F> Identität Spring Nut/Hook/Audi Schraube
[Prozeß KAB Midfill (Silicone 6 identity Spring Nut/Hook/Au- F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] di Schraube faulty not observed end of charge AA developing and imple- 2 control plan: 100% inspec- 4 (64) Fiedler, Jens, TE2 IAB;
identification is not possible menting in practice tion Gottschalk, Markus, TX1;
of the airbag and / or of com- QM IAU / IAU, QM IAU / IAT;
ponents QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
Insert)] sign
BMG Freigabe
a limited extent
Insert)]
identification of the airbag fixed define batches
and / or components wrong Fiedler, Jens, TE2 IAB
Insert)]
Systemelement (System element): Clip Checking
Merkmal (Characteristic): <F> Vorhandensein aller Clips mit Package Supports
[Prozeß KAB Midfill (Silicone 8 Clip not available F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (32) Gottschalk, Markus, TX1;
installation in the vehicle ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
is not possible ( visible ) ( nance plan QM, QM IAT / IAU;
LAH.DUM.880.BF ) QM, QM IAT / IAU
TE2 Wien, TE2 Wien
ergonomic workplace design QM IAU / IAU, QM IAU / IAT
BMG Freigabe
TE2 Wien, TE2 Wien control plan: periodic sen-
scanning with (camera sen- QM, QM IAT / IAU
sor interrogation clips / packa- control plan: 100% inspec-
ge support / hook) tion
[Prozeß KAB Midfill (Silicone 10 package support not availa- F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] ble not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. nance plan QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
Insert)] TE2 Wien, TE2 Wien control plan: periodic sen-
installation in the vehicle sor test with test pieces
is not possible ( visible ) ( QM, QM IAT / IAU
scanning with (camera sen-
LAH.DUM.880.BF )
[Prozeß KAB Midfill (Silicone 10 attachment strap not in the F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] correct position not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. nance plan QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
Merkmal (Characteristic): <F> Rastzustand Clip / Package Support
[Prozeß KAB Midfill (Silicone 5 rest state Clip / Package Sup- F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] port NOK not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
unnecessary prolongation of ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
the cycle time / lead time nance plan QM, QM IAT / IAU;
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
Merkmal (Characteristic): <F> Abstand Referenzpunkt zu Clippunkte / Metal Hook (Cushion Folded)
[Prozeß KAB Midfill (Silicone 8 distance reference point to F [Clip Device]
Insert)] clips / Metal Hook NOK ( distance reference point to
installation in the vehicle About conditioning ensured ) the clip / Metal Hook NOK
is not possible ( visible ) (
LAH.DUM.880.BF )
Merkmal (Characteristic): <F> Vorhandensein Metal Hook
[Prozeß KAB Midfill (Silicone 10 availability of the metal hook F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] NOK not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
seek time is too long (LAH. ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
DUM.880.BF) nance plan QM, QM IAT / IAU;
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
TE2 Wien, TE2 Wien control plan: periodic sen- unbearbeitet (untouched)
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Tracebility system] Maßnahmenstand - Anfang (Initial state): 20.09.2012
Insert)] bogus process and product specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
process stop (only losing ti- parameters, as well as well adaptation / adaptation of pro- Massinger, Jörgen Michael,
me , no rework the product as standard information / ope- Massinger, Jörgen Michael, IT
necessary) rational data ( eg , compo- ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
committee dule number ) visualize and PASS system after release
fed against changes
adaptation / adaptation of pro- Massinger, Jörgen Michael, IT Massinger, Jörgen Michael,
results
fed against changes
adaptation / adaptation of pro- Massinger, Jörgen Michael, IT Massinger, Jörgen Michael,
results
fed against changes
make wrong use of decision
^ ^ ^ ^ ^ ^ ^ specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 7 faulty process / interruptions [Tracebility system] adaptation / adaptation of pro- Massinger, Jörgen Michael,
Insert)] make wrong use of decision ven series HW and SW com- IT;
committee ponets (for examble AU 316) machine acceptance report QM, QM IAT / IAU
results
fed against changes
not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (28) Gottschalk, Markus, TX1;
nance plan QM, QM IAT / IAU;
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
the wrong program at the plausiblity test of sensor on 2 machine acceptance report 2 (28) Massinger, Jörgen Michael,
right armor the armor module to the loa- results IT;
ded program QM, QM IAT / IAU
QM, QM IAT / IAU
BMG Freigabe
(unbearbeitet (untouched)) periodic sensor check (error
no process start possible
Verantwortlich? (Responsi-
ble?)
Termin? (Deadline?)
Insert)]
Merkmal (Characteristic): <S> Orientierung Orientierungbalken
[Prozeß KAB Midfill (Silicone 8 orientation of the orientation S [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
Insert)] bar NOK (test) not eingeklipt vollstängig AA developing and implemen- 2 implementation of machine 2 (32) Gottschalk, Markus, TX1;
installation in the vehicle ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
is not possible ( visible ) ( nance plan QM, QM IAT / IAU;
LAH.DUM.880.BF ) QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
Systemelement (System element): Final Inspection + Internal Packaging ASM Cushion Folded
Merkmal (Characteristic): Complete Components
[Prozeß KAB Midfill (Silicone 10 Complete Components NOK
Insert)]
Airbag inflates when trigge-
Insert)]
DUM.880.BF , use safety)
Insert)]
DUM.880.BF)
Insert)]
880.BF )
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
Insert)]
noise when driving (rattling,
creaking etc.) (LAH.DUM.
880.BF)
[Prozeß KAB Midfill (Silicone 7 faulty process/ interruptions [Operator Final Inspection] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] (committee) defective packing of the
committee ASM Cushion Folded in a de-
fined position and packaging
^ ^ ^ ^ ^ ^ ^ AA developing and implemen- 2 visual detection end of 2 (28) Massinger, Jörgen Michael,
[Prozeß KAB Midfill (Silicone 7 faulty process/ interruptions [Operator Final Inspection] ting in practice the packaging (display) IT;
Insert)] (committee) defective packing of the QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU Massinger, Jörgen Michael, IT
committee ASM Cushion Folded in a de- QM, QM IAT / IAU
fined position and packaging employee qualifications: to
BMG Freigabe
[Prozeß KAB Midfill (Silicone 6 faulty process/ interruptions [Operator Final Inspection] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] (rework) defective packing of the AA developing and implemen- 2 visual detection end of 2 (24) Massinger, Jörgen Michael,
process stop (rework on pro- ASM Cushion Folded in a de- ting in practice the packaging (display) IT;
duct possible / required) fined position and packaging QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
BMG Freigabe
[Operator Final Inspection] Maßnahmenstand - Anfang (Initial state): 04.07.2013
do not checks the number of AA developing and implemen- 2 visual inspection in further 2 (24) QM IAU / IAU, QM IAU / IAT;
parts in the kennel with the ting in practice process according AA QM, QM IAT / IAU
document from PASS
separating parts are genera- cess lead to faulty adaptation / adaptation of pro- Massinger, Jörgen Michael,
ted upon deployment (LAH. Massinger, Jörgen Michael, IT
DUM.880.BF) ponets (for examble AU 316) implementation of machine QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 6 acceptance results / mainte-
Insert)] nance plan
identification is not possible PASS system after release QM IAU / IAU, QM IAU / IAT
process stop with n.i.O. cha- records results of the pro- specifications: adoption and 2 plausibility check of data 2 (40) Gottschalk, Markus, TX1;
racterization (part blocked) cess cycle defective / not on adaptation / adaptation of pro- Massinger, Jörgen Michael, IT Massinger, Jörgen Michael,
ponets (for examble AU 316) implementation of machine QM IAU / IAU, QM IAU / IAT
acceptance results / mainte-
nance plan
PASS system after release QM IAU / IAU, QM IAU / IAT
fed against changes
Funktion (Function): trouble-free process in the logistics
[Prozeß KAB Midfill (Silicone 2 faulty process in the logistics [Operator Final Inspection] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] sector Fails to submit the document AA developing and implemen- 2 visual inspection in further 2 (8) QM IAU / IAU, QM IAU / IAT;
process stop in the internal lo- to the transport box from ting in practice process according AA QM, QM IAT / IAU
gistics
Systemelement (System element): Final Inspection + Packaging ASM Module
Merkmal (Characteristic): Produkt IO
[Prozeß KAB Midfill (Silicone 6 product NOK [Operator] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] defective packing of the AA developing and implemen- 2 visual detection end of the 2 (24) Massinger, Jörgen Michael,
not comply with require- ASM Cushion Folded in a de- ting in practice packaging (display) IT;
ments optics fined position and packaging QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
employee qualifications: to TE2 Wien, TE2 Wien
BMG Freigabe
and demonstrably trained per- unbearbeitet (untouched)
ergonomic workplace design
TE2 Wien, TE2 Wien
defining appropriate delivery
[Prozeß KAB Midfill (Silicone 5 faulty process/ interruptions [Operator] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] (rework) defective packing of the AA developing and implemen- 2 visual detection end of the 2 (20) Massinger, Jörgen Michael,
unnecessary prolongation of ASM Cushion Folded in a de- ting in practice packaging (display) IT;
the cycle time / lead time fined position and packaging QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU;
employee qualifications: to TE2 Wien, TE2 Wien
make sure that exclusively BMG Freigabe
and demonstrably trained per- unbearbeitet (untouched)
ergonomic workplace design
TE2 Wien, TE2 Wien
defining appropriate delivery
Funktion (Function): trouble-free process in the logistics
[Prozeß KAB Midfill (Silicone 2 faulty process in the logistics [Operator] Maßnahmenstand - Anfang (Initial state): 04.07.2013
Insert)] sector Fails to submit the document
process stop in the internal lo- to the transport box from
gistics
^ ^ ^ ^ ^ ^ ^ AA developing and implemen- 2 visual inspection in further 2 (8) QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 2 faulty process in the logistics [Operator] ting in practice process according AA QM, QM IAT / IAU
Insert)] sector Fails to submit the document QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT BMG Freigabe
process stop in the internal lo- to the transport box from unbearbeitet (untouched)
gistics employee qualifications: to
sets from the wrong docu- AA developing and implemen- 2 visual inspection in further 2 (8) QM IAU / IAU, QM IAU / IAT;
ment ting in practice process according AA QM, QM IAT / IAU
color printer paper define
(diff LHS / RHS)
batch number of the batch
packaging to adjust Part Num-
ber (LH part number is odd -
> Batch number odd)
identification is not possible cess lead to faulty adaptation / adaptation of pro- Massinger, Jörgen Michael,
of the airbag and / or of com- Massinger, Jörgen Michael, IT
ponents ponets (for examble AU 316) implementation of machine QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 8 acceptance results / mainte-
Insert)] nance plan
identification of the airbag PASS system after release QM IAU / IAU, QM IAU / IAT
and / or components wrong of the validated algorithms sa-
fed against changes
identification of the airbag [Tracebility system] Maßnahmenstand - Anfang (Initial state): 20.09.2012
and / or components only records results of the pro- specifications: adoption and 2 plausibility check of data 2 (32) Gottschalk, Markus, TX1;
with increased effor cess cycle defective / not on adaptation / adaptation of pro- Massinger, Jörgen Michael, IT Massinger, Jörgen Michael,
ponets (for examble AU 316) implementation of machine QM IAU / IAU, QM IAU / IAT
nance plan
PASS system after release QM IAU / IAU, QM IAU / IAT
fed against changes
Systemelement (System element): Allgemeine Prozessparameter
Merkmal (Characteristic): Umgebungstemperatur (Umwelteinflüsse)
[Prozeß KAB Midfill (Silicone 4 unacceptably high ambient
Insert)] temperature
process upset - no further pro-
cessing possible
Merkmal (Characteristic): Lichtstärke (Umwelteinflüsse)
[Prozeß KAB Midfill (Silicone 4 impermissible light intensity
Insert)] effects (sunlight)
process upset - no further pro-
cessing possible
Funktion (Function): meet cleanliness requirements
Systemelement (System element): Tether Cutting

Merkmal (Characteristic): Zuschnitt (Tetherband) auf definierte Länge
[Prozeß KAB Midfill (Silicone 5 cutting too short [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] cut lengths wrong employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- make sure that exclusively stancil ( layer) QM, QM IAT / IAU
me , no rework the product and demonstrably trained per-
necessary) QM IAU / IAU, QM IAU / IAT BMG Freigabe
committee
[Prozeß KAB Midfill (Silicone 5 ting in practice
Insert)]
unnecessary prolongation of QM, QM IAT / IAU
the cycle time / lead time [Device] Maßnahmenstand - Anfang (Initial state): 24.02.2014
does not implement defined AA developing and implemen- 2 process monitoring by opera- 2 (28) QM IAU / IAU, QM IAU / IAT;
parameters ting in practice tor according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
BMG Freigabe
maintenance plan
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 5 cutting too long [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] cut lengths wrong employee qualifications: to 2 first piece testing/ check with 2 (40) QM IAU / IAU, QM IAU / IAT;
given space in the vehicle is make sure that exclusively stancil ( layer) QM, QM IAT / IAU
exceeded (Package) (LAH. and demonstrably trained per-
DUM.880.BF) QM IAU / IAU, QM IAU / IAT BMG Freigabe
correctly possible (not visible AA developing and implemen-
) ( LAH.DUM.880.BF ) ting in practice
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 cutting too long [Device] 2 QM IAU / IAU, QM IAU / IAT 2 (40) unbearbeitet (untouched)
Insert)] does not implement defined
installation in the vehicle in- parameters
maintenance plan
TE2 Wien, TE2 Wien
Merkmal (Characteristic): keine ausgefranste Kanten
[Prozeß KAB Midfill (Silicone 7 frayed edges [Operator] Maßnahmenstand - Anfang (Initial state): 07.03.2014
Insert)] cutting method incorrectly employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
committee make sure that exclusively stancil ( layer) QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
TE2 Wien, TE2 Wien
BMG Freigabe
maintenance plan
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 7 faulty process / interruptions [Tetherrolle] Maßnahmenstand - Anfang (Initial state): 20.09.2012
committee fied drawing UPS with delivered parts QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 5 QM, QM IAA QM, QM IAT / IAU BMG Freigabe
process stop (only losing ti-
me , no rework the product [Device] Maßnahmenstand - Anfang (Initial state): 24.02.2014
necessary) does not implement defined AA developing and implemen- 2 process monitoring by opera- 2 (28) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
unnecessary prolongation of BMG Freigabe
the cycle time / lead time unbearbeitet (untouched)
maintenance plan
TE2 Wien, TE2 Wien
Systemelement (System element): Die Cutting
Merkmal (Characteristic): Zuschnitt
[Prozeß KAB Midfill (Silicone 5 Cutting NOK [Device] Maßnahmenstand - Anfang (Initial state): 24.02.2014
Insert)] does not implement defined AA developing and implemen- 2 process monitoring by opera- 2 (28) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- parameters ting in practice tor according to AA QM, QM IAT / IAU;
me , no rework the product TE2 Wien, TE2 Wien
necessary) QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
BMG Freigabe
committee and demonstrably trained per-
Insert)]
unnecessary prolongation of QM IAU / IAU, QM IAU / IAT
the cycle time / lead time maintenance plan
TE2 Wien, TE2 Wien
number of layers defined not employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
stack make sure that exclusively stancil ( layer) QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
not fix defined layer stacks employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
by means of clamps make sure that exclusively stancil ( layer) QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
do not position location employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
packages / faulty make sure that exclusively stancil ( layer) QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
Merkmal (Characteristic): keine ausgefranste Kanten
[Prozeß KAB Midfill (Silicone 7 frayed edges [Device] Maßnahmenstand - Anfang (Initial state): 24.02.2014
Insert)] does not implement defined AA developing and implemen- 2 process monitoring by opera- 2 (28) QM IAU / IAU, QM IAU / IAT;
committee parameters ting in practice tor according to AA QM, QM IAT / IAU;
TE2 Wien, TE2 Wien
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ BMG Freigabe
[Prozeß KAB Midfill (Silicone 7 frayed edges [Device] 2 QM IAU / IAU, QM IAU / IAT 2 (28) unbearbeitet (untouched)
Insert)] does not implement defined
committee parameters
maintenance plan
TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 7 faulty process / interruptions [Coverlagen] Maßnahmenstand - Anfang (Initial state): 20.09.2012
committee fied drawing UPS with delivered parts QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 5 QM, QM IAA QM, QM IAT / IAU BMG Freigabe
process stop (only losing ti-
me , no rework the product [Device] Maßnahmenstand - Anfang (Initial state): 24.02.2014
necessary) does not implement defined AA developing and implemen- 2 process monitoring by opera- 2 (28) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien
unnecessary prolongation of BMG Freigabe
the cycle time / lead time unbearbeitet (untouched)
maintenance plan
TE2 Wien, TE2 Wien
wrong upgrade employee qualifications: to 2 first piece testing/ check with 2 (28) QM IAU / IAU, QM IAU / IAT;
make sure that exclusively stancil (set-up process) QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
Systemelement (System element): Module Final Assembly
Merkmal (Characteristic): <S> Positionierung Cushion Folded zu Inflator
[Prozeß KAB Midfill (Silicone 10 incorrect positioning Cushion [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] Folded to Inflator Inflator Pre Assembled employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- wrong position in device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. and demonstrably trained per- nance plan QM, QM IAT / IAU
880.BF , use safety ) sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
[Prozeß KAB Midfill (Silicone 10 plemented (quality matrix) unbearbeitet (untouched)
Insert)] control plan: periodic sen-
is not complied with (LAH. AA developing and implemen- QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 QM, QM IAT / IAU tion
Insert)] specifications: a constructive QM IAU / IAU, QM IAU / IAT
seek time is too long (LAH. solution for positioning (cente-
DUM.880.BF) ring on)
Insert)]
scanning (inductive on cente-
880.BF )
ring)
Insert)]
life too short (LAH.DUM.880. specifications: ensure,
BF) through software process
step end
filling gas flows directly into [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
vehicle interior do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 10 sembled in Device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
Insert)] and demonstrably trained per- nance plan QM, QM IAT / IAU
separating parts are genera- sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ted upon deployment (LAH. plemented (quality matrix) unbearbeitet (untouched)
DUM.880.BF) control plan: periodic sen-
Insert)]
ting in practice
committee control plan: 100% inspec-
S specifications: a constructive QM IAU / IAU, QM IAU / IAT
solution for fixing aid axial (ra-
dially rotatable pivot bearing)
specifications: query (rota-
ry bearing on investment)
specifications: ensure,
through software process
step end
diffusor stop ( direction 180 ° employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
) does not bring diffuser to po- make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
sition and demonstrably trained per- nance plan QM, QM IAT / IAU
ting in practice
scanning (inductive position /
alignment slide)
solution for positioning (positi-
on after rotating diffusor)
not move with the expanding
collet the Silicone Insert at
the beginning of the diffusor /
false
^ ^ ^ ^ ^S ^ ^ employee qualifications: to 8 implementation of machine 2 (160) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 7 incorrect positioning Cushion [Operator] make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
Insert)] Folded to Inflator not move with the expanding and demonstrably trained per- nance plan QM, QM IAT / IAU
committee collet the Silicone Insert at sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
the beginning of the diffusor / plemented (quality matrix) unbearbeitet (untouched)
false control plan: periodic sen-
ting in practice
specifications: sensor que- QM IAU / IAU, QM IAU / IAT
ry (query diffuser position sen-
sor in the further process)
securing strap part 2 position employee qualifications: to 4 sensor scan in another pro- 4 (160) QM IAU / IAU, QM IAU / IAT;
on not the retainerbox and make sure that exclusively cess (position sensor) QM, QM IAT / IAU;
the securing strap part 1 and demonstrably trained per- TE2 Wien, TE2 Wien
TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
not introduced a securing employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
unit between retainer box make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
and securing strap part 1 and demonstrably trained per- nance plan QM, QM IAT / IAU
BMG Freigabe
BMG Freigabe control plan: periodic sen-
(unbearbeitet (untouched)) sor check
ting in practice
BMG Freigabe
QM, QM IAT / IAU (unbearbeitet (untouched))
BMG Freigabe control plan: 100% inspec-
(unbearbeitet (untouched)) tion
scanning (inductive slide in fi-
nal position) BMG Freigabe
BMG Freigabe
specifications: sensor que-
ry (lever assembly aid (secu-
ring unit 0 °)
BMG Freigabe
specifications: additional
bracing of the securing strap
part 2 by means of an assem-
bly aid
BMG Freigabe
(verworfen (rejected))
step end
BMG Freigabe
Merkmal (Characteristic): <S> Positionierung Securing Unit
[Prozeß KAB Midfill (Silicone 10 false axial positioning Secu- [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] ring Unit Inflator Pre Assembled employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
seek time is too long (LAH. solution for positioning (cente-
DUM.880.BF) ring on)
Insert)]
880.BF )
ring)
Insert)]
life too short (LAH.DUM.880. specifications: ensure,
BF) through software process
step end
[Prozeß KAB Midfill (Silicone 10 S
filling gas flows directly into [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
vehicle interior do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 10 sembled in Device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
Insert)] and demonstrably trained per- nance plan QM, QM IAT / IAU
separating parts are genera- sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ted upon deployment (LAH. plemented (quality matrix) unbearbeitet (untouched)
DUM.880.BF) control plan: periodic sen-
Insert)]
ting in practice
committee control plan: 100% inspec-
specifications: a constructive QM IAU / IAU, QM IAU / IAT
step end
^ ^ ^ ^ ^S ^ Gottschalk, Markus, TX1 ^[...] ^[...] ^[...] ^[...] ^[...]
[Prozeß KAB Midfill (Silicone 7 false axial positioning Secu- [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] ring Unit diffusor stop ( direction 180 °
committee employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
) does not bring diffuser to po- make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
alignment slide)
solution for positioning (positi-
on after rotating diffusor)
BMG Freigabe
ting in practice
BMG Freigabe
BMG Freigabe
ring unit 0 °)
BMG Freigabe
bly aid
BMG Freigabe
step end
BMG Freigabe
do not turn the securing unit employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
by 60 ° with installation aid to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
stop and demonstrably trained per- nance plan QM, QM IAT / IAU
ting in practice
scanning (inductive position
lever assembly aid in end po-
sition)
step end
Merkmal (Characteristic): <S> Fixierung Securing Unit
[Prozeß KAB Midfill (Silicone 10 no fixing Securing Unit S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- sembled in Device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
seek time is too long (LAH. solution for fixing aid axial (ra-
DUM.880.BF) dially rotatable pivot bearing)
Insert)]
880.BF )
Insert)] specifications: ensure,
life too short (LAH.DUM.880. through software process
BF) step end
Insert)] [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
filling gas flows directly into diffusor stop ( direction 180 ° employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
vehicle interior ) does not bring diffuser to po- make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 ^ ^S ^ ^ ^ ^ [...] ^ ^ ^[...]
Insert)] no fixing Securing Unit [Operator] employee qualifications: to 2 2 (40)
separating parts are genera- diffusor stop ( direction 180 ° [...] unbearbeitet (untouched)
ted upon deployment (LAH. ) does not bring diffuser to po- control plan: periodic sen-
sition QM IAU / IAU, QM IAU / IAT sor check
DUM.880.BF)
ting in practice
Insert)] control plan: 100% inspec-
noise when driving (rattling, QM, QM IAT / IAU tion
creaking etc.) (LAH.DUM. specifications: sensor
880.BF) QM IAU / IAU, QM IAU / IAT
[Prozeß KAB Midfill (Silicone 7 alignment slide)
committee
[Prozeß KAB Midfill (Silicone 5 solution for positioning (positi-
Insert)] on after rotating diffusor)
the cycle time / lead time Gottschalk, Markus, TX1
BMG Freigabe
ting in practice
BMG Freigabe
BMG Freigabe
ring unit 0 °)
BMG Freigabe
bly aid
BMG Freigabe
step end
BMG Freigabe
do not turn the securing unit employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
by 60 ° with installation aid to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
stop and demonstrably trained per- nance plan QM, QM IAT / IAU
ting in practice
scanning (inductive position
lever assembly aid in end po-
sition)
step end
Merkmal (Characteristic): <S> Positionierung des Diffusors im Silicone Insert
[Prozeß KAB Midfill (Silicone 10 incorrect positioning of the dif- S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] fusor in the silicones insert not move with the expanding employee qualifications: to 8 implementation of machine 2 (160) Gottschalk, Markus, TX1;
Airbag inflates when trigger collet the Silicone Insert at make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
not ( LAH.DUM.880.BF ) the beginning of the diffusor / and demonstrably trained per- nance plan QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 false sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
Insert)] plemented (quality matrix) unbearbeitet (untouched)
Airbag inflates when trigge- control plan: periodic sen-
880.BF , use safety ) AA developing and implemen- QM, QM IAT / IAU
ting in practice
Insert)] QM, QM IAT / IAU tion
seek time is too long (LAH. specifications: sensor que- QM IAU / IAU, QM IAU / IAT
DUM.880.BF) ry (query diffuser position sen-
[Prozeß KAB Midfill (Silicone 10 sor in the further process)
880.BF )
Merkmal (Characteristic): Unbeschädigte Spreizzange
[Prozeß KAB Midfill (Silicone 5 damaged expanding collet [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] damage during joining , Ex- employee qualifications: to 8 implementation of machine 2 (80) Gottschalk, Markus, TX1;
unnecessary prolongation of panding make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
the cycle time / lead time and demonstrably trained per- nance plan QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 4 sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
process upset - no further pro- control plan: periodic sen-
cessing possible
ting in practice
scanning with (completeness
forceps tips)
^ ^ ^ ^ ^ [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
[Prozeß KAB Midfill (Silicone 4 damaged expanding collet damage during removal, Ex- employee qualifications: to 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
Insert)] panding make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
process upset - no further pro- and demonstrably trained per- nance plan QM, QM IAT / IAU
cessing possible sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
scanning (inductive integrity
for forceps tips)
step end
Merkmal (Characteristic): <S> Positionierung Securing Strap Part 1 auf Diffusor
[Prozeß KAB Midfill (Silicone 10 no / incorrect positioning Se- S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] curing Strap Part 1 on diffu- position wrong securing employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- sor strap part 1 from below via make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. the diffusor and demonstrably trained per- nance plan QM, QM IAT / IAU
Insert)] specifications: sensor QM IAU / IAU, QM IAU / IAT
seek time is too long (LAH. scanning (inductive sensor:
DUM.880.BF) presence SSP1)
Insert)]
880.BF )
step end
Insert)]
life too short (LAH.DUM.880. specifications: sensor que-
BF) ry (query diffuser position sen-
sor in the further process)
vehicle interior
Merkmal (Characteristic): <S> Positionierung / Fixierung Securing Strap Part 3 am Clamp Hook
[Prozeß KAB Midfill (Silicone 10 no positioning Securing S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] Strap Part 3 on Clamp Hook do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Insert)]
880.BF )
BF) step end
TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
securing strap 3 position / fix employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
wrong make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
scanning (camera sensor pre-
sence / position securing
strap part 3)
step end
[Prozeß KAB Midfill (Silicone 10 incorrect positioning Secu- S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] ring Strap Part 3 on Clamp Inflator Pre Assembled employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- Hook wrong position in device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
[Prozeß KAB Midfill (Silicone 10 ^ ^S ^ ^ ^ [...] ^ ^ ^
Insert)] incorrect positioning Secu- [Operator] specifications: a constructive 2 2 (40) BMG Freigabe
filling gas flows directly into ring Strap Part 3 on Clamp Inflator Pre Assembled solution for positioning (cente-
vehicle interior Hook wrong position in device ring on)
ring)
step end
do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
sembled in Device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
step end
TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
securing strap 3 position / fix employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
wrong make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
scanning (camera sensor pre-
sence / position securing
strap part 3)
step end
[Prozeß KAB Midfill (Silicone 10 no fixing Securing Strap Part S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] 3 on Clamp Hook do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Insert)]
880.BF )
BF) step end
Insert)]
vehicle interior
Insert)]
DUM.880.BF)
[Prozeß KAB Midfill (Silicone 10 incorrect fixation Securing S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] Strap Part 3 on Clamp Hook Inflator Pre Assembled employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
separating parts are genera- solution for positioning (cente-
ted upon deployment (LAH. ring on)
DUM.880.BF)
^ ^ ^ ^ ^S ^ ^ Gottschalk, Markus, TX1 ^ ^ ^ ^ ^
[Prozeß KAB Midfill (Silicone 10 incorrect fixation Securing [Operator] specifications: sensor 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
Insert)] Strap Part 3 on Clamp Hook Inflator Pre Assembled unbearbeitet (untouched)
separating parts are genera- wrong position in device ring)
DUM.880.BF) Gottschalk, Markus, TX1
step end
do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
sembled in Device make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
step end
[Prozeß KAB Midfill (Silicone faulty assembly cover connec- [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] tion not perform flap on the cover employee qualifications: to 2 implementation of machine 2 (24) Gottschalk, Markus, TX1;
installation in the vehicle diffi- with Securing Strap 3 make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
cult possible and demonstrably trained per- nance plan QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 6 sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
noise when driving (rattling, control plan: periodic sen-
creaking etc.) (LAH.DUM.
880.BF) AA developing and implemen- QM, QM IAT / IAU
ting in practice
sor position / presence of co-
ver flap)
step end
out flap on the cover wrong employee qualifications: to 2 implementation of machine 2 (24) Gottschalk, Markus, TX1;
by the air bag make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
sor position / presence of co-
ver flap)
step end
Merkmal (Characteristic): <S> Positionierung Inflator- Strap
[Prozeß KAB Midfill (Silicone 10 Inflator not positioning strap S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] position of the inflator - Strap employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Airbag inflates when trigge- Cushion Folded over Inflator make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ring undefined ( LAH.DUM. behind Clamp Screw is and demonstrably trained per- nance plan QM, QM IAT / IAU
880.BF , use safety ) wrong sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
scanning (presence inflator
strap)
step end
[Prozeß KAB Midfill (Silicone 10 incorrect positioning Inflator S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] Strap do not lock Inflator Pre As- employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
^ ^ ^ ^ ^S ^ ^ specifications: ensure, ^ ^ ^ ^ ^
[Prozeß KAB Midfill (Silicone 10 incorrect positioning Inflator [Operator] through software process 2 QM IAU / IAU, QM IAU / IAT 2 (40) BMG Freigabe
Insert)] Strap do not lock Inflator Pre As- step end unbearbeitet (untouched)
Default deployment direction sembled in Device Gottschalk, Markus, TX1
DUM.880.BF , use safety) [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
position of the inflator - Strap employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Cushion Folded over Inflator make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
behind Clamp Screw is and demonstrably trained per- nance plan QM, QM IAT / IAU
wrong sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
scanning (presence inflator
strap)
step end
Insert)] (committee) incorrectly measuring the po- employee qualifications: to 6 implementation of machine 2 (84) Gottschalk, Markus, TX1;
committee sition number behind diffusor make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
sor)
step end
does not stick module la- process description: just 2 review 2 (28) Fiedler, Jens, TE2 IAB;
bel a label exists, OK about scan- QM IAU / IAU, QM IAU / IAT
ners BMG Freigabe
Fiedler, Jens, TE2 IAB unbearbeitet (untouched)
tion
securing strap part 2 by employee qualifications: to 4 sensor scan in another pro- 4 (112) QM IAU / IAU, QM IAU / IAT;
strap pull not pull to align the make sure that exclusively cess (position sensor) QM, QM IAT / IAU;
silicone insert in the direction and demonstrably trained per- TE2 Wien, TE2 Wien
retainer box TE2 Wien, TE2 Wien
ting in practice
QM, QM IAT / IAU
Insert)] (rework) incorrectly measuring the po- employee qualifications: to 6 implementation of machine 2 (72) Gottschalk, Markus, TX1;
process stop (rework on pro- sition number behind diffusor make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
duct possible / required) and demonstrably trained per- nance plan QM, QM IAT / IAU
ting in practice
sor)
step end
ners BMG Freigabe
tion
Insert)] damaged during removal employee qualifications: 3 control in the final inspecti- 3 (45) QM IAU / IAU, QM IAU / IAT;
unnecessary prolongation of to make sure that exclusively on of the ASM modules accor- QM, QM IAT / IAU
the cycle time / lead time and demonstrably trained per- ding to AA BMG Freigabe
menting in practice
QM, QM IAT / IAU
Inflator not turn in pivot bea- employee qualifications: to 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
ring 180 ° and fix it with make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
clamps and additional protec- and demonstrably trained per- nance plan QM, QM IAT / IAU
tion via toggle sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
ting in practice
QM, QM IAT / IAU
^ ^ ^ ^ ^ ^ ^ specifications: a constructive ^ ^ ^ ^ ^
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Operator] solution for positioning fixing 2 QM IAU / IAU, QM IAU / IAT 2 (20) BMG Freigabe
Insert)] Inflator not turn in pivot bea- aid (inflator rotation) unbearbeitet (untouched)
unnecessary prolongation of ring 180 ° and fix it with Gottschalk, Markus, TX1
the cycle time / lead time clamps and additional protec-
tion via toggle specifications: ensure,
step end
expanding collet not store in employee qualifications: to 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
devicve make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
scanning (query presence
pliers)
step end
do not position the securing employee qualifications: to 2 implementation of machine 2 (20) Gottschalk, Markus, TX1;
unit on the mounting help make sure that exclusively acceptance results / mainte- Konstruktion, TE2;
and demonstrably trained per- nance plan QM IAU / IAU, QM IAU / IAT;
sor check
ting in practice
specifications: structurally QM IAU / IAU, QM IAU / IAT
Poka Yoke soln securing unit
Konstruktion, TE2
specifications: structurally
Poka Yoke soln assembly aid
scan (optical sensor pre-
sence on mounting aid)
step end
incorrectly measuring the po- employee qualifications: to 6 implementation of machine 2 (60) Gottschalk, Markus, TX1;
sition number behind diffusor make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ting in practice
sor)
step end
positioned module label incor- AA developing and imple- 2 control plan: 100% inspec- 3 (30) QM IAU / IAU, QM IAU / IAT;
rectly menting in practice tion QM, QM IAT / IAU
employee qualifications: control plan: 100% final in-
to make sure that exclusively spection
[Securing Unit] Maßnahmenstand - Anfang (Initial state): 20.09.2012
ble?)
ponets (for examble AU 316) QM, QM IAT / IAU
Termin? (Deadline?)
BMG Freigabe machine acceptance report
(unbearbeitet (untouched)) results
PASS system after release QM, QM IAT / IAU
fed against changes BMG Freigabe
BMG Freigabe
ble?)
Termin? (Deadline?)
^ ^ ^ ^ ^ ^ ^ BMG Freigabe ^ machine acceptance report ^ ^ ^
[Prozeß KAB Midfill (Silicone 5 faulty process / interruptions [Tracebility system] (unbearbeitet (untouched)) 2 results 2 (20) BMG Freigabe
Insert)] specify steps wrong PASS system after release unbearbeitet (untouched)
unnecessary prolongation of QM, QM IAT / IAU
the cycle time / lead time fed against changes BMG Freigabe
BMG Freigabe
Merkmal (Characteristic): <F> Identität Securing Unit
[Prozeß KAB Midfill (Silicone 5 false / no identity Screw F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
identification of the airbag and do not enter as required menting in practice tion Gottschalk, Markus, TX1;
and / or components only batch number ( Bracket) QM IAU / IAU, QM IAU / IAT;
with increased effor QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
ergonomic workplace de- TE2 Wien, TE2 Wien
sign
BMG Freigabe
TE2 Wien, TE2 Wien unbearbeitet (untouched)
ners BMG Freigabe
tion
sticks incorrect module la- process description: just 2 control plan: 100% inspec- 4 (40) Fiedler, Jens, TE2 IAB;
bel on a label exists, OK about scan- tion Gottschalk, Markus, TX1;
ners QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
Fiedler, Jens, TE2 IAB implementation of machi-
BMG Freigabe
AA developing and imple- ne acceptance results / main-
menting in practice tenance plan
specifications: against
scan in device
print quality is poor (not wi- printer Maintenance 2 control plan: 100 % negative 2 (20) Chonlatarn, Wachira, BL IAT;
thin a label , smeared , dirty, . scanning QM IAU / IAU, QM IAU / IAT;
.) QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU
about check printer settings QM, QM IAT / IAU
BMG Freigabe
Chonlatarn, Wachira, BL IAT unbearbeitet (untouched)
Merkmal (Characteristic): <F> Identität Inflator Pre Assembled
[Prozeß KAB Midfill (Silicone 5 false / no identity Inflator Pre F [Operator] Maßnahmenstand - Anfang (Initial state): 21.09.2012
Insert)] Assembled does not stick module la- process description: just 2 review 2 (20) Fiedler, Jens, TE2 IAB;
identification of the airbag bel a label exists, OK about scan- QM IAU / IAU, QM IAU / IAT
and / or components only QM IAU / IAU, QM IAU / IAT
ners BMG Freigabe
with increased effor control plan: 100% inspec-
tion
QM, QM IAT / IAU
BMG Freigabe
scan in device
QM, QM IAT / IAU
BMG Freigabe
Merkmal (Characteristic): <F> Identität ASM Cushion Folded
[Prozeß KAB Midfill (Silicone 5 wrong / no identity ASM cushi- F [Operator] Maßnahmenstand - Anfang (Initial state): 21.09.2012
Insert)] on folded does not stick module la- process description: just 2 review 2 (20) Fiedler, Jens, TE2 IAB;
identification of the airbag bel a label exists, OK about scan- QM IAU / IAU, QM IAU / IAT
and / or components only QM IAU / IAU, QM IAU / IAT
ners BMG Freigabe
with increased effor control plan: 100% inspec-
tion
QM, QM IAT / IAU
BMG Freigabe
scan in device
QM, QM IAT / IAU
BMG Freigabe
Merkmal (Characteristic): <F> gelabeltes Modul
[Prozeß KAB Midfill (Silicone 6 isolate labeled wrong modu- F [Operator] Maßnahmenstand - Anfang (Initial state): 21.09.2012
Insert)] le (position) positioned module label incor- AA developing and imple- 2 control plan: 100% inspec- 3 (48) QM IAU / IAU, QM IAU / IAT;
identification of the airbag rectly menting in practice tion QM, QM IAT / IAU
a limited extent QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT BMG Freigabe
[Prozeß KAB Midfill (Silicone 8 ^ ^ ^F ^ ^ employee qualifications: ^ control plan: 100% final in- ^ ^ ^
Insert)] isolate labeled wrong modu- [Operator] to make sure that exclusively 2 spection 3 (48) BMG Freigabe
identification of the airbag le (position) positioned module label incor- and demonstrably trained per- unbearbeitet (untouched)
and / or components wrong rectly sonnel this process step im-
Systemelement (System element): Inflator Pre Assembly
Merkmal (Characteristic): <F> Position Clamps auf Inflator Abstand Refezenzpunkt Clamp Hook (Modulzeichnung F 12, Winkellage Clamp Hook / Screw Inflator
[Prozeß KAB Midfill (Silicone 10 axially rotated by 180° (F)* [Operator] Maßnahmenstand - Anfang (Initial state): 29.11.2012
Insert)] adds Clamp Hook AA developing and implemen- 3 3 (90) Gottschalk, Markus, TX1;
process stop at the custo- ting in practice QM IAU / IAU, QM IAU / IAT;
mer (return required) QM, QM IAT / IAU
QM, QM IAT / IAU
Insert)] employee qualifications: to
process stop (rework on pro- make sure that exclusively
duct possible / required) and demonstrably trained per-
Insert)]
installation in the vehicle QM IAU / IAU, QM IAU / IAT
is not possible ( visible ) ( specifications: a constructi-
LAH.DUM.880.BF ) ve solution for positioning (Po-
ka Yoke Clamp Hook /
Screw)
[Prozeß KAB Midfill (Silicone 6 twisted radially (F)* [Operator] Maßnahmenstand - Anfang (Initial state): 17.07.2012
Insert)] positioned Inflator and specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
process stop (rework on pro- Clamps in device wrong ve solution for positioning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
duct possible / required) (Clamp Screw / Hook) nance plan QM, QM IAT / IAU
process stop at the custo- specifications: sensors control plan: 100% inspec-
mer (return required) scanning (torque screw dri- tion
ving) QM IAU / IAU, QM IAU / IAT
Insert)] Gottschalk, Markus, TX1 control plan: periodic sen-
installation in the vehicle employee qualifications: to sor check
is not possible ( visible ) ( make sure that exclusively QM, QM IAT / IAU
LAH.DUM.880.BF ) and demonstrably trained per-
ting in practice
QM, QM IAT / IAU
Inflator is not fixed in device specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
ve solution for fixation Infla- acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
tor (toggle) nance plan QM, QM IAT / IAU
specifications: sensor control plan: 100% inspec-
scanning (inductive sensors tion
diffuser generator fixation) QM IAU / IAU, QM IAU / IAT
Gottschalk, Markus, TX1 control plan: periodic sen-
employee qualifications: to sor check
make sure that exclusively QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
screw threaded incorrectly employee qualifications: 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
and demonstrably trained per- nance plan QM, QM IAT / IAU;
control plan: periodic sensor
check
ting in practice
NOK part process parame-
QM, QM IAT / IAU ters not achieved
specifications: torque-angle TE2 Wien, TE2 Wien
query
step end
ting in practice
QM, QM IAT / IAU
screw threaded incorrectly employee qualifications: to 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
check
ting in practice
query
step end
ting in practice
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 6 axial position incorrectly (F)* [Operator] Maßnahmenstand - Anfang (Initial state): 17.07.2012
Insert)] positioned Inflator and specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
process stop (rework on pro- Clamps in device wrong ve solution for positioning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
duct possible / required) (Clamp Screw / Hook) nance plan QM, QM IAT / IAU
process stop at the custo- specifications: sensors control plan: 100% inspec-
mer (return required) scanning (torque screw dri- tion
Insert)] Gottschalk, Markus, TX1 control plan: periodic sen-
installation in the vehicle employee qualifications: to sor check
is not possible ( visible ) ( make sure that exclusively QM, QM IAT / IAU
LAH.DUM.880.BF ) and demonstrably trained per-
ting in practice
QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
screw threaded incorrectly employee qualifications: 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
check
ting in practice
query
step end
ting in practice
QM, QM IAT / IAU
check
ting in practice
query
step end
ting in practice
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 6 clamp hook / screw reversed
Insert)] ( not structurally possible
process stop (rework on pro- plant )
duct possible / required)
Insert)]
process stop at the custo-
Insert)]
installation in the vehicle
LAH.DUM.880.BF )
[Prozeß KAB Midfill (Silicone 6 two equal clamps mounted
Insert)] (not structurally possible
process stop (rework on pro- plant)
duct possible / required)
Insert)]
Insert)]
installation in the vehicle
LAH.DUM.880.BF )
[Prozeß KAB Midfill (Silicone 6 not positioned (F)* [Operator] Maßnahmenstand - Anfang (Initial state): 29.11.2012
Insert)] does not add / false Clamp AA developing and implemen- 3 implementation of machine 3 (90) Gottschalk, Markus, TX1;
process stop (rework on pro- Hook on Inflator ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
duct possible / required) nance plan QM, QM IAT / IAU
QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 10 ^ ^(F)* ^ ^ ^ QM IAU / IAU, QM IAU / IAT ^ ^ BMG Freigabe
Insert)] not positioned [Operator] employee qualifications: to 3 3 (90) unbearbeitet (untouched)
process stop at the custo- does not add / false Clamp make sure that exclusively control plan: 100% inspec-
mer (return required) Hook on Inflator and demonstrably trained per- tion
installation in the vehicle QM IAU / IAU, QM IAU / IAT sor check
is not possible ( visible ) ( specifications: a constructi- QM, QM IAT / IAU
LAH.DUM.880.BF ) ve solution for positioning (Po-
ka Yoke Clamp Hook)
specifications: sensor (tor-
que screw driving)
does not add / false Clamp AA developing and implemen- 3 implementation of machine 3 (90) Gottschalk, Markus, TX1;
Screw on Inflator ting in practice acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
QM, QM IAT / IAU
make sure that exclusively control plan: 100% inspec-
and demonstrably trained per- tion
specifications: a constructi- QM, QM IAT / IAU
ve solution for positioning (Po-
ka Yoke Clamp Screw)
specifications: sensor (tor-
que screw driving)
positioned Inflator and specifications: a constructi- 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
Clamps in device wrong ve solution for positioning acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
(Clamp Screw / Hook) nance plan QM, QM IAT / IAU
specifications: sensors control plan: 100% inspec-
scanning (torque screw dri- tion
ting in practice
QM, QM IAT / IAU
ting in practice
QM, QM IAT / IAU
Merkmal (Characteristic): <S> Drehmoment
[Prozeß KAB Midfill (Silicone 10 torque / not competent to S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] stand trial screw threaded incorrectly employee qualifications: 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
separating parts are genera- to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ted upon deployment (LAH. and demonstrably trained per- nance plan QM, QM IAT / IAU;
DUM.880.BF) sonnel this process step im- TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 6 plemented (quality matrix) BMG Freigabe
Insert)] control plan: periodic sensor
noise when driving (rattling, check
creaking etc.) (LAH.DUM. AA developing and implemen- QM, QM IAT / IAU
880.BF) ting in practice
query
step end
ting in practice
QM, QM IAT / IAU
check
ting in practice
query
step end
^ ^ ^ ^ ^S ^ ^ Gottschalk, Markus, TX1 ^ ^ ^ ^ ^
[Prozeß KAB Midfill (Silicone 6 torque / not competent to [Operator] AA developing and implemen- 2 TE2 Wien, TE2 Wien 2 (40) BMG Freigabe
Insert)] stand trial screw threaded incorrectly unbearbeitet (untouched)
ting in practice
[...]
QM, QM IAT / IAU
Merkmal (Characteristic): <S> Drehwinkel
[Prozeß KAB Midfill (Silicone 10 angle of rotation wrong / not S [Operator] Maßnahmenstand - Anfang (Initial state): 30.11.2012
Insert)] competent to stand trial screw threaded incorrectly employee qualifications: 2 implementation of machine 2 (40) Gottschalk, Markus, TX1;
separating parts are genera- to make sure that exclusively acceptance results / mainte- QM IAU / IAU, QM IAU / IAT;
ted upon deployment (LAH. and demonstrably trained per- nance plan QM, QM IAT / IAU;
DUM.880.BF) sonnel this process step im- TE2 Wien, TE2 Wien
[Prozeß KAB Midfill (Silicone 6 plemented (quality matrix) BMG Freigabe
Insert)] control plan: periodic sensor
noise when driving (rattling, check
creaking etc.) (LAH.DUM. AA developing and implemen- QM, QM IAT / IAU
880.BF) ting in practice
[Prozeß KAB Midfill (Silicone 7 QM, QM IAT / IAU ters not achieved
Insert)] specifications: torque-angle TE2 Wien, TE2 Wien
committee query
Insert)]
step end
ting in practice
QM, QM IAT / IAU
control plan: periodic sensor unbearbeitet (untouched)
QM IAU / IAU, QM IAU / IAT check
ting in practice
query
step end
ting in practice
QM, QM IAT / IAU
Merkmal (Characteristic): <F> Identität Clamps
[Prozeß KAB Midfill (Silicone 6 false / no identity Clamps F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
identification is not possible menting in practice tion Gottschalk, Markus, TX1;
of the airbag and / or of com- QM IAU / IAU, QM IAU / IAT;
ponents QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
Insert)] sign
BMG Freigabe
process stop with n.i.O. cha- TE2 Wien, TE2 Wien unbearbeitet (untouched)
Merkmal (Characteristic): <F> Identität Inflator
[Prozeß KAB Midfill (Silicone 5 false / no identity Inflator F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
and / or components only QM IAU / IAU, QM IAU / IAT;
with increased effor QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
ergonomic workplace de- TE2 Wien, TE2 Wien
sign
BMG Freigabe
TE2 Wien, TE2 Wien unbearbeitet (untouched)
Merkmal (Characteristic): <F> Identität Screw
[Prozeß KAB Midfill (Silicone 6 false / no identity Screw F [Operator] Maßnahmenstand - Anfang (Initial state): 20.11.2012
and / or components only to QM IAU / IAU, QM IAU / IAT;
a limited extent QM, QM IAT / IAU QM IAU / IAU, QM IAU / IAT
QM, QM IAT / IAU;
Insert)] sign
BMG Freigabe
of the airbag and / or of com- as standard information / ope- Verantwortlich? (Responsi-
ponents rational data ( eg , compo- ble?)
[Prozeß KAB Midfill (Silicone 5 nent identification data , da- Termin? (Deadline?)
dule number ) visualize and unbearbeitet (untouched)
identification of the airbag BMG Freigabe machine acceptance report
and / or components only store (unbearbeitet (untouched)) results
with increased effor PASS system after release QM, QM IAT / IAU
[Prozeß KAB Midfill (Silicone 7 of the validated algorithms sa-
process stop with n.i.O. cha- Massinger, Jörgen Michael, IT
racterization (part blocked) BMG Freigabe
Insert)] will not invest in transport con- employee qualifications: to 2 control in the final inspecti- 2 (28) QM IAU / IAU, QM IAU / IAT;
process stop (only losing ti- tainers Inflator Pre Assemb- make sure that exclusively on of the ASM modules accor- QM, QM IAT / IAU;
me , no rework the product led and demonstrably trained per- ding to AA TE2 Wien, TE2 Wien
necessary) sonnel this process step im- QM IAU / IAU, QM IAU / IAT BMG Freigabe
committee
menting in practice
QM, QM IAT / IAU
ergonomic workplace de-
sign
TE2 Wien, TE2 Wien
damage when placed in trans- employee qualifications: to 2 control in the final inspecti- 2 (28) QM IAU / IAU, QM IAU / IAT;
port containers make sure that exclusively on of the ASM modules accor- QM, QM IAT / IAU;
and demonstrably trained per- ding to AA TE2 Wien, TE2 Wien
menting in practice
QM, QM IAT / IAU
ergonomic workplace de-
sign
TE2 Wien, TE2 Wien
make wrong use of decision specifications: adoption and 2 plausibility check of data 2 (28) Gottschalk, Markus, TX1;
ven series HW and SW com- ble?) IT;
Termin? (Deadline?)
Gottschalk, Markus, TX1 (unbearbeitet (untouched)) BMG Freigabe
BMG Freigabe
as standard information / ope- Verantwortlich? (Responsi-
ven series HW and SW com- ble?) IT;
rational data ( eg , compo- ponets (for examble AU 316) QM, QM IAT / IAU
nent identification data , da- Termin? (Deadline?)
dule number ) visualize and unbearbeitet (untouched)
store (unbearbeitet (untouched)) results
BMG Freigabe
[Clamp Screw] Maßnahmenstand - Anfang (Initial state): 20.09.2012
[Inflator] Maßnahmenstand - Anfang (Initial state): 20.09.2012
adaptation / adaptation of pro- Verantwortlich? (Responsi- Massinger, Jörgen Michael,
ble?)
Termin? (Deadline?)
BMG Freigabe
ble?)
Termin? (Deadline?)
BMG Freigabe
[Clamp Hook] Maßnahmenstand - Anfang (Initial state): 20.09.2012
[Screw] Maßnahmenstand - Anfang (Initial state): 20.09.2012
adds Clamp Screw
^ ^ ^ ^ ^ ^ ^ AA developing and implemen- 3 1 (21) Gottschalk, Markus, TX1;
[Prozeß KAB Midfill (Silicone 7 faulty process / interruptions [Operator] ting in practice QM IAU / IAU, QM IAU / IAT;
Insert)] adds Clamp Screw QM, QM IAT / IAU
QM, QM IAT / IAU
specifications: a constructi-
ve solution for positioning (Po-
ka Yoke Clamp Hook /
Screw)
Merkmal (Characteristic): <S> Massewiderstand IO
[Prozeß KAB Midfill (Silicone 10 mass resistance NOK S [Operator] Maßnahmenstand - Anfang (Initial state): 29.07.2010
Insert)] no conductive transition bet- ground resistance test medi- 3 implementation of machine 2 (60) QM IAU / IAU, QM IAU / IAT;
Airbag inflates when trigger ween bracket and generator um PASS ensured acceptance results / mainte- TE2 Wien, TE2 Wien
not ( LAH.DUM.880.BF ) nance plan
[Prozeß KAB Midfill (Silicone 10 QM IAU / IAU, QM IAU / IAT unbearbeitet (untouched)
Insert)]
Airbag inflates when trigge- [Operator] Maßnahmenstand - Anfang (Initial state): 29.07.2010
ring undefined ( LAH.DUM. unsuitable Tester - not remo- test equipment acceptance 2 ground resistance test medi- 2 (40) QM IAU / IAU, QM IAU / IAT
880.BF , use safety ) ved correctly (MSA) um PASS ensured BMG Freigabe
implementation of machine unbearbeitet (untouched)
nance plan
not applied test via analog card 2 ground resistance test medi- 2 (40) QM IAU / IAU, QM IAU / IAT;
TE2 Wien, TE2 Wien um PASS ensured TE2 Wien, TE2 Wien
nance plan

AU 536 P-FMEA Form Sheet Eng Variation 2

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AU 536 P-FMEA Form Sheet Eng Variation 2

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AU 536 P-FMEA Form Sheet Eng Variation 2

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F M E A (F M E A) Nummer (Number): 1.1.

Funktion (Function): streak air pockets between fabric sheets

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien

[Prozeß KAB Midfill (Silicone 10 helper of the insertion in devi-

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

maintenance plan QM IAU / IAU, QM IAU / IAT

TE2 Wien, TE2 Wien needle selection compared

QM IAU / IAU, QM IAU / IAT

Systemelement (System element): Tether Cutting

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