front end assembly procedure volvo trucks
DESCRIPTION
Example of POKE YOKE in Assy using Red/Green light visuals for detection and air cut offTRANSCRIPT
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
• Problem: Customer (Volvo) 8D several
reoccurring quality issues 1. Missing front plate, not assy
11 defects in 3 different shipments over 1 month period.
No Assy instructions.
Solution: Develop SOP using Assy drawing and
POKE YOKE the Assy process with Red/Green Light
visual and Air cut off
RESULTS: ZERO DEFECTS 8 shipments (4 months)
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1Ju 7Front End Assembly Cell
20904633
FRAME
EXTENSION
FRONT
DIAGRAM 5
STEP #9 FIT THE OTHER FRONT FRAME EXTENSION (20904633)
INTO PLACE ON TOP. (REF. DIAGRAM 5)
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1Production Improvement Team 1
CAR M310330ASSEMBLY
Front End Assembly Cell
21125557
RH FRAME
EXTENSION
21125555
LH FRAME
EXTENSION
27QL299M
(25176484)
TOW HOOK
RIGHT HAND
27QL299M2
(25176483)
TOW HOOK
LEFT HAND
STEP #1 - PLACE THE LEFT AND
RIGHT HAND FRAME EXTENSIONS
ONTO THE FIXTURE ON THEIR SIDE
AS SHOWN IN DIAGRAM 1.
STEP #2 - INSERT THE INDICATED
TOW HOOK INTO EACH SIDE.
PLACE THESE WITH THE HUCK
SPIN BOLTS ALREADY IN PLACE, INTO
THE HOLES IN EACH FRAME
EXTENSION. (4AM23 IS A LONGER
HUCK SPIN BOLT AND IS PLACED
CLOSEST TO THE CURVE IN THE
HOOK. THE UPPER HUCK SPIN BOLT
IS 4AM22) REFER TO DIAGRAM 2
4AM22
(25164087)
HUCK SPIN
BOLT4AM23
(25166332)
HUCK SPIN
BOLT
DIAGRAM 2
DIAGRAM 1
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14Front End Assembly Cell
159AM3
HUCKSPIN COLLAR
STEP #3 - PLACE 1 HUCK SPIN COLLAR (159AM3) ON EACH HUCK
SPIN BOLT THREADED THROUGH THE TOW HOOKS
(REF - DIAGRAM 3)
STEP#4 - TIGHTEN ALL 4 HUCK SPIN COLLARS USING
THE HUCK BOLT GUN.
DIAGRAM 3
159AM3
HUCKSPIN COLLAR
CAR M310330ASSEMBLY
2
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
21 3Front End Assembly Cell
CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT
STEP #5 - STAND THE FRAME EXTENSION
21125557 UP, AND PLACE ON THE LOCATING
PINS OF THE FIXTURE.
STEP #6 - FIT THE FRONT FRAME EXTENSION
(21125482) INTO PLACE WITH THE RH FRAME
EXTENSION (21125557) (REF. DIAGRAM 4)
STEP #7 FIT THE FRONT FRAME EXTENSION
(21125482) INTO PLACE ON THE LH FRAME
EXTENSION (21125555)
STEP #8 PLACE LH FRAME EXTENSION ONTO
THE LOCATING PINS ON THE FIXTURE.
DIAGRAM 4
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
CRITICAL COMPONENT 21125482 FRAME EXTENSION FRONT. RED light normally ON. If
missing component, RED light will remain ON and air is shut-off.
POKE YOKE CHECK --> IF
COMPONENT IS NOT PRESENT, CANNOT
TORQUE THE BOLTS (SHUT-OFF VALVE)
4Front End Assembly Cell
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Lift the Front End Extension and place it on the spacer bar to assist with assembly of the LH
side. The spacebar activates the sensor and rhe light turns GREEN
5Front End Assembly Cell
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
ASSEMBLED FRONT END EXTENSION
6Front End Assembly Cell
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1 8Front End Assembly Cell
STEP #10 INSERT THE SPACER BAR ONTO THE ASSEMBLY AS SHOWN ABOVE
TO STABALIZE THE PART.
RELIABLE METHOD: HOLES ON THE SPACER BAR
MUST LINE UP WITH THE HOLES ON THE FRAME
EXTENSIONS.
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31 9Front End Assembly Cell
STEP #11 INSERT 1 FLANGE SCREW (27AM99) PER SIDE THROUGH THE
INDICATED HOLE IN 21125482 AND EACH FRAME EXTENSION.
STEP #12 SECURE EACH FLANGE SCREW BY HAND USING 1 FLANGE
LOCK NUT EACH.(191AM13)
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1 10Front End Assembly Cell
VIEW FROM
BACKSIDE
OF ASSEMBLY
STEP #13 INSERT 2 FLANGE SCREWS (27AM99) PER SIDE
THROUGH THE FRONT FRAME EXTENSION AND THE LH AND
RH FRAME EXTENSIONS.
STEP #14 SECURE THESE 4 FLANGE SCREWS BY HAND
USING 1 FLANGE LOCK NUT PER SCREW (191AM13)
FRONT VIEW OF ASSEMBLY
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1 11Front End Assembly Cell
1 PER SIDE OF
191AM13 - 981040 - NUT
27AM131 - 975209 - BOLT
IN SAME LOCATION EACH SIDE
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1Front End Assembly Cell
STEP #15 INSERT 2 FLANGE SCREWS (975204) PER SIDE THROUGH THE FRONT FRAME
EXTENSION AND THE LH AND RH FRAME EXTENSIONS. (REF. DIAGRAM 6 BELOW)
STEP #16 SECURE THESE 4 SCREWS BY HAND WITH FLANGE NUT 976432
12
DIAGRAM 6
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1 13Front End Assembly Cell
27AM99 - 975121 - BOLT
191AM13 - 981040 - NUT
975204 - BOLT
189AM16 - 976432 - NUT
BOLT PLACEMENT DIAGRAM
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
1 14Front End Assembly Cell
STEP #17 PLACE THE APPROPRIATE
EXTENSION ON THE TORQUE GUN.
STEP #18 WITH MINIMUM TORQUE,
TIGHTEN THE TWO SCREWS
(27AM99) THAT WERE PREVIOUSLY
PLACED INTO THE TOP OF THE
ASSEMBLY TO SECURE THE
20904633 TO THE RH AND LH
FRAME EXTENSIONS.
RELIABLE METHOD
FLANGE SCREW 975209 IS
SECURED FIRST TO AVOID
FURTHER MOVEMENT OF
THE ASSEMBLY WHILE TIGHTENING
THE OTHER SCREWS
STEP #19 TIGHTEN ALL OTHER SCREWS
WITH MINIMUM TORQUE SO THEY ARE
NUT RUNNER TIGHT.
STEP #20 REMOVE THE SPACER BAR
STEP #21 LOAD PART ONTO SKID
USING THE HOIST.
COMPLETED PART
CAR M310330ASSEMBLY
Department Reference #
Confirmed By Process Owner Date Chapter Rev. PageIssuer
Front End Assembly - 21222124
31Julian Kalac QA Manager02/24/14
CAR M310330ASSEMBLY
Front End Assembly Cell