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Measurement & Inspection


ning progressive assemblies of stampings as they became a door, Wall measures areas that could go in and out of tolerance during the process. He then uses individual scans of each part and digitally assembles them, which he termed it a ‘Digital Meisterbock.’ This helps to identify inter- ferences between the parts not apparent either in CAD interference checks or with point measurement techniques. Chrysler also has enhanced its launch process to include a series of quality gates, held roughly every month until Job One. Management reports, fre- quently updated, provide the basis for these quality reviews. “We feed a ‘stop- light’ report to upper management every week,” Wall said. The Cp


A SUBSIDIARY OF and Cpk of a


subset of critical characteristics (CCs) are computed from measurements. The stoplight term comes from the use of red (bad), yellow (on-notice), and green (good) measures attached to each CC, a common practice in automotive OEMs, using Cp


and Cpk thresholds. Another action tool the Metrology


Center established was a way to track and monitor critical tooling points that affect the 447 CCs established in the control plan. At Toledo Assembly, for example, the plant contains 900 ro- bots, of which over 131 stations alone are dedicated to geometry setting. Chrysler developed a tool they call the X-Matrix to map those 447 CCs to the specific station on the shop floor that controls their quality. “Then we take it to the next step and figure out which component inside that tool is actually controlling that [CC],” he said. Even with perfect parts that will ideally fit to- gether perfectly, imperfection in these tools will introduce variation. To eliminate this last potential source of variation, Chrysler introduced on-going maintenance in a disciplined fashion. “In the past, we would receive


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shipment of completed automated assembly tools for the body shop from the OEM tooling source, we would certify it one time and install it, and that would be it,” Cole said. Now Chrysler maintains the equipment proactively. “We do this


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September 2013 | ManufacturingEngineeringMedia.com 79


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