Issue Level Page

STK2734
Prototype Pre-Launch Production 16
1 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Customer: Key Contact/Phone: Core Team:

Lee Blake, Angela Patterson, (JLR)

Land Rover Mick Turner Benoit Peltier, Gary Marshall, Sam Prince Jim Birks, Kayleigh Pepper, Tracy
01782645300 Biddulph, Simon Edwards (Autoneum)
Project: L550
Part Name: Part No: Drawing No: Engineering Level / Date:

HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
Supplier / Plant: Supplier Code: Control Plan Issued By:

AUTONEUM GB LTD
STOKE ON TRENT
STAFFORDSHIRE
D0N7B Simon Edwards
ENGLAND

Machine / Device / Tools For Manufacture:

Heater, Forming Press, Foaming Booth, Water Jet Cutter

Date (Revision) Revision Details Revised By Date (Revision) Revision Details Revised By

08/04/2014 Control Plan compiled Sam Prince 20/04/2017 (9) Reviewed & Updated for PRSS 08-17, PRSS 09-17 & PRSS 11-17 T.Biddulph

10/06/14 (2) Drawing updates Sam Prince 06/06/2017 (10) CCC marking check location corrected S.Edwards

26/09/14 (3) Drawing updates, clip detection added Sam Prince 15/02/2018 (11) Annual Review T.Biddulph

17/12/14 (4) Checking frequencies revised Sam Prince 27/02/2018 (12) Reviewed for PRSS 93-17 - Incorrect Part labels. K.Pepper
Removal of Anti Sub block Check from inspection. Now included
08/10/2015 (5) Jim Birks 13/03/2018 (13) Minor corrections following process Audit. S.Edwards
in Op 40 - Fit EPP Blocks and Apply Foam
PRSS 72-15 Incorrect part labels - Include the 1st of label
18/01/16 (6) K.Pepper 22/10/2018 (14) Reviewed for PRSS 106/116-18 J.Birks
validation check
28/04/2016 (7) Updated for 17MY Simon Edwards 05/12/2018 (15) Reviewed for PRSS 138-18 (Foam Bleed)
T.Biddulph /
14/02/2017 Scheduled Review 22/05/2019 (16) Reviewed for PRSS 62-19 (Missing Stud) J.Birks
S.Edwards

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
2 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Visual inspection
Check incoming Visual check on
as defined in Quarantine delivery, inform
Damaged goods for damage Goods Inwards incoming Every
Preparation No Damage 100% Receiving Logistics Manager & Quality,
packaging to packaging or Personnel materials & delivery
Receive Raw Material Inspection possible Supplier collection
material packaging
Pre-Laminated Carpet Blank Procedure
Ebony Confirm that Visual check that Visual inspection
Lunar materials delivered goods received as defined in Quarantine delivery, inform
Delivery note Goods Inwards
OP 10 Correct to Order comply with comply with the 100% Each batch Receiving Logistics Manager & Quality,
Poly/Iso compliance Personnel
10.1 Suppliers delivery Delivery Note Inspection possible Supplier collection
note Procedure
Assembled Parts
Submarine Block
Incoming
Clips
Confirm materials materials to be Quarantine material, dispose
Rear clips Delivered Each Verification to C of
Correct to Order are correct to Supplier checked against 100% of in line with NCP / CAR
Materials delivery C
specifications Certificate of System
Conformance

Visual
FIFO procedure to
assessment to Handling, Storage Quarantine material, dispose
Conforms to be supported to Each
Material Blanks Stores Personnel check date 100% & Packing of in line with NCP / CAR
Specification maintain function delivery
sequence, Procedure System
of raw materials
process audits
Material Storage
10.2
Visual
FIFO procedure to
assessment to Handling, Storage Quarantine material, dispose
Conform to be supported to Each
Bought Out Parts Stores Personnel check date 100% & Packing of in line with NCP / CAR
Specification maintain function delivery
sequence, Procedure System
of raw materials
process audits

Handling, Storage
Visual
FIFO procedure to Every & Packing
assessment to Return material to stores &
Issue Materials to production First In / First Out be supported to batch Procedure
10.3 Stock rotation Stores personnel check date 100% issue correct stock level to
cell (FIFO) maintain function issued to Identification and
sequence, shop floor
of raw materials shop floor Traceability
process audits
Procedure

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
3 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Parts to be
Stored to Prevent available in the Each Handling, Storage
Material Storage
10.4 All Materials Damage and production area to Associates Visual 100% Production & Packing Obtain Material from stores
Production Area
deterioration facilitate Run Procedure
Production

Visual check of At start of Check set up to Process

Manually set to
Refer to Process Production settings against every Process Record Record Sheet and reset, if
Cycle Time Process Record 100%
Record Sheet Associates Process Record production Sheet necessary, consult Team
Sheet
Sheet run Leader & Process Engineer

Prepare Cell for Production

Run Verification of At each Check set up to Process
Temperature Manually set to Production Process Record
Heater set up Refer to Process settings against tooling Record Sheet and reset, if
Setting Top Process Record Associate / Team 100% Sheet
Record Sheet Process Record change necessary, consult Team
Sheet Leader
Sheet over Leader & Process Engineer

Verification of At each Check set up to Process

Manually set to Production Process Record
Temperature Refer to Process settings against tooling Record Sheet and reset, if
Process Record Associate / Team 100% Sheet
Setting Bottom Record Sheet Process Record change necessary, consult Team
Sheet Leader
Sheet over Leader & Process Engineer

As defined on the
Load correct tool Tool correctly Tool correctly Each Process Record Reset tool as appropriate.
Tool Change Process Record
for Part Number loaded and loaded and 100% Production Sheet / Standard
Associate Sheet / Standard
being produced functional functional Run Ops Inform Tool Maintenance.
Ops

Tool No's. Check that tooling As defined on the Each Process Record Raise maintenance requisition
Tool Change
Press Tool 5 Fixed is clean & in good Process Record 100% Production Sheet form if required, cleaning or
Associate
Change/Maintenance 5/7 Slide working order Sheet Run repair to be carried out
Tool
Tool fit for use Visual check to
maintenance
Check that correct confirm tool Each Process Record
Production Replace tooling with correct
Part tool is fitted to complies with 100% Production Sheet / Shop
Associate tool to manufacture parts
Press parts to be Run Order
produced

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
4 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Plant to undergo
Maintenance
periodic checks As defined Total Productive Raise maintenance requisition
Maintenance checks carried out
incorporating 12 100% in TPM Maintenance form (contingency plans may
Department & recorded in
monthly overhaul plan Procedure have to be implemented)
machine logbook
Planned (if necessary)
maintenance
Maintenance
Each Raise maintenance requisition
Plant to undergo Production checks to be Process Record
100% Production form & inform Maintenance
daily checks Associates carried out & Sheet & TPM
Run Dept.
recorded

At each
Correct press Generic program Production tooling Process Record
Carpet program Not Applicable 100% Stop / Call / Wait
program for all parts Associate change Sheet
over

At each
start up
Visual check of Check set up to Process
Manually set to and after
Press maintenance & set up Press Refer to Process Production settings against Process Record Record Sheet and reset, if
Cycle/Dwell Time Process Record N/A each
Record Sheet Associates Process Record Sheet necessary, consult Team
Sheet product
Sheet Leader & Process Engineer
change
over

At each
start up
Visual check of Check set up to Process
and after
Tool Refer to Process Generic setting for Production settings against Process Record Record Sheet and reset, if
N/A each
Temperature Record Sheet all parts Associates Process Record Sheet necessary, consult Team
product
Sheet Leader & Process Engineer
change
over
10.5
At each
start up
Visual check of Check set up to Process
Manually set to and after
Press Opening Refer to Process Production settings against Process Record Record Sheet and reset, if
Process Record N/A each
Height. Record Sheet Associates Process Record Sheet necessary, consult Team
Sheet product
Sheet Leader & Process Engineer
change
over

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
5 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
10.5 HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Load correct tool Tool correctly Tool correctly As defined on the Each Reset tool as appropriate.
Tool Change Process Record
for Part Number loaded and loaded and Process Record 100% Production
Associate Sheet
being produced functional functional Sheet Run Inform Tool Maintenance.

At each
start up
Verification of Process Record Check set up to Process
Manually set to Tool Change and after
Shot weight - Refer to Process settings against Sheet Record Sheet and reset, if
Process Record Associate / Team N/A each
Booth 1 Record Sheet Process Record necessary, consult Team
Sheet Leader product
Sheet Leader & Process Engineer
change
over

At each
start up
Verification of Process Record Check set up to Process
Foam Booth 1 Manually set to Tool Change and after
Shot weight - Refer to Process settings against Sheet Record Sheet and reset, if
Process Record Associate / Team N/A each
Booth 2 Record Sheet Process Record necessary, consult Team
Foam Booth 2 Sheet Leader product
Sheet Leader & Process Engineer
change
Foam Booth set up over
Foam Tool
5 Fixed
At each
5/7 Slide start up
Verification of Process Record Check set up to Process
Manually set to Production and after
Refer to Process settings against Sheet Record Sheet and reset, if
Cycle/Dwell Time Process Record Associates / N/A each
Record Sheet Process Record necessary, consult Team
Sheet Team Leader product
Sheet Leader & Process Engineer
change
over

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
6 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
Foam Booth 1 HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Foam Booth 2
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Foam Booth set up
Main Floor Carpet Rear - 5 Seat Fixed
Foam Tool(& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
5 Fixed HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
5/7 Slide
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

At each
start up
Verification of Process Record Check set up to Process
and after
Refer to Process Generic setting for Production settings against Sheet Record Sheet and reset, if
C0² Charging N/A each
Record Sheet all parts Associates Process Record necessary, consult Team
product
Sheet Leader & Process Engineer
change
over

Verification of At each Process Record Check set up to Process

Temperature Manually set to Production
Refer to Process settings against tooling Sheet Record Sheet and reset, if
Setting Process Record Associates / N/A
Record Sheet Process Record change necessary, consult Team
Top Tool Sheet Team Leader
Sheet over Leader & Process Engineer

Visual check to
At start of
Check that correct confirm nest
Water Jet Nest Nest loaded and Production each Process Record Replace nest with correct nest
Water jet nest nest is fitted to complies with 100%
functional Associate production Sheet to manufacture parts
water jet parts to be
5 Fixed run
produced
Water Jet set up
Visual check to
5/7 Slide At start of
Correct program Check correct confirm plug Process Record
Water jet Production each Replace program plug with
plug program plug is complies with 100% Sheet / Binary
program Associate production correct plug
fitted parts to be Plug board
run
produced

Correct Raw Tufted

Verification of
Material blank is Carpet/FBR Shop
Verify Raw Production materials to Shop Each batch Request correct material from
used Blanks Check materials 100% Order/Process
Material Associate Order / Process of material raw material storage area
Ebony Record Sheet
Record Sheet
Lunar

Load Pre-
Load Pre- Each
laminated Blank Production Visual Re-position material as
Correctly loaded Laminated Blank 100% material Standard Ops
on heater belt Associate assessment instructed
Pile Up Film Down blank
Op20 Heat Pre-Laminated Blank

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
7 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Op20 Heat Pre-Laminated Blank

Validation of
Heater cycle time At the start
Refer to Process Process Record Production settings against Process Record
and temperature 100% of every Stop, Call, Wait
Record Sheet Sheet Associate Process Record Sheet
setting shift.
Sheet

Each
Stop production, inform Team
1 off formed Production Automated length of Process governed
Op 30 Form part Press Cycle Press Cycles 100% Leader & Process Engineer
Rear/press cycle Associate process material by press cycle
for machine reset
fed into tool

Verification of
Shop Order /
Verify Raw Correct EPP Production materials to Shop Each batch Request correct material from
Check materials 100% Process Record
Material Block is used Associate Order / Process of material raw material storage area
Sheet
Record Sheet

Foam plant In case of malfunction each

Verify Crash Pad Crash pad fitted Visual check of
should not Production Poka Yoke part to be marked with a pen
sensor is CC enables foam plant process without 100% At start up
operate without Associate Camera system dot as having crash pads
functional to run crash pad fitted
crash pad fitted verified in carpet

Visual check for

Fit anti sub insert Each
Present and 1 anti sub Production correct loading Poka Yoke Re-position heel tripper block
(x2) into foam CC 100% formed
Fit EPP Blocks and Apply correctly located block/foot well Associate onto location Camera system onto location dowel
Op 40 tool front carpet
Foam dowels

Verification of At start of Process Record Check Set Up to Process

Production
Foaming booth 1 foamed settings against every Sheet Record Sheet and reset, if
Apply foam Associates / 100%
cycle part/booth cycle Process Record production Necessary, Consult Team
Team Leader
Sheet run Leader & Process Engineer

Correct Rework As per Rework Team Leader / Visual As per Rework Re- Inspect & Re-Introduce /
Foam Rework 100% As required
Method Instruction SPO assessment Instruction Scrap Part

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
8 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Op 40 MainFitFloor
EPP Carpet
Blocks and Apply
Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Foam Rear - 7 Seat Sliding (& Japan)
Main Floor Carpet HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

CCC marking CCC marking Each

Apply CCC Production Visual As per Customer Re-fit/clean CCC marking
present and CC incorporated into 100% formed
Marking Associate assessment Specification plate in tool
legible on carpet foam tool carpet

Load part onto Ensure part is Production Visual Each

100% Std Ops Re-load water jet nest
Water Jet Nest water jet nest loaded correctly Associate assessment formed part

5 Fixed Process governed

Op 50 Water Jet cut by water jet cycle .
5/7 Slide Program
Production Automated Each
Cut part Water jet program 100% determined by Re-select correct program
Associate process formed part
Harting Plugs
fitted into the
water jet skins

Visual check of
Mat Clips Check materials to materials to Process Record
Verify raw Production Each batch Request correct material from
Rear Clips Process Record Process Record 100% Sheet / Shop
materials Associate of material raw material storage area
Sheet / Shop Order Sheet / Shop Order
Order
Std Ops
Mat clips fit to 2 clips in both foot Check clips fitted Each Inspection
Clips fitted into Production Standard
both rear carpet wells securely by pull 100% formed Refit clip as per specification
water jet cut slots Associates
foot wells test carpet

Std Ops
Each Inspection
Production Standard
Clip detection rig 100% formed Refit clip as per specification
Associates
carpet

Std Ops
Op 60 Fit Mat Clips Clipping Fixture Poka yoke device Each Inspection
Production
fitted to clipping 100% formed Standard Refit clip as per specification
Associates
rig carpet

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
9 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
Op 60 Fit Mat Clips Clipping Fixture
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Label fitted as per Each

Production Visual Re-attach label as per
Label fitted Customer 100% formed Std Ops
Associates assessment instruction
specification carpet

Label part number 1st off and Confirm shop order on

Visual
and description Production at printer Label verification process - dispose of incorrect
Apply label Correct label assessment and 100%
correct to the Associates media check sheet labels and then generate
"Buddy" Check
physical carpet change correct labels

Human readable
Label detail characters legible Production Visual Std Ops / Visual
100% Each Label Stop / Call / Wait
legible. and barcodes Associates assessment Standard
uninterrupted
Std Ops
Clips fitted into Poka yoke device Each Inspection
Fit Rear mating clips (7 Seat Additional 7 Seat Rear clips fitted Clips fitted in rear Production
60a water jet cut fitted to clipping 100% formed Standard Refit clip as per specification
Only) Clipping Fixture to rear of carpet of carpet Associates
holes rig carpet

Each
Production Visual Inspection
Contour Contour stability 100% formed
Associates assessment Standard
carpet
Identify Condition any defects
reject & record as per
1st / Last off /
Standard Ops . Any three
Periphery After Breaks Checking Fixture /
Each consecutive defects Stop /
& Approved 3D Production Checking fixture Inspection
formed Call / Wait
cut out Checking Fixture Associates check All 4 Cavities & Standards
carpet
dimensions visually during
production
Checking Fixture

5 Fixed Check finished part

Identify Condition any defects
for tears, Inspection
Op 70 Inspection Each reject & record as per
Defects delamination, short Production Visual Standard
100% formed Standard Ops . Any three
5/7 Slide foam shot, voids, Associates assessment
carpet consecutive defects Stop /
strikethrough, Visual Aids
Call / Wait
creases etc.

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 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
10 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
Checking Fixture HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
5 Fixed
CHARACTERISTICS METHODS
Op 70 Inspection
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG,5/7 SlideFOR
TOOLS CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Check all slugs Inspection

Each
Slugs have been Production Visual Standard
100% formed Remove slugs from cut-outs
None Permissible removed from cut- Associates assessment
carpet
outs Visual Aids

After any waterjet Run water jet

After each
Dirt/debris on mods check parts Production Visual through cycle Re-run cycle without carpet in
100% water jet
carpet for dirt/debris from Associates assessment without carpet nest
mod
cutting nest fitted

Autoneum
Quality STJLR51.5341 &
personnel to Drawing / Annual
STJLR51.5341 & As specified in
acquire part(s) Validation Raise NCR, inform Quality
Annual Testing Drawing Customer Every Year
and Schedule Manager
Specification
arrange testing
with accredited Sufficient parts Pass / Fail
Material source
Testing Laboratory to complete all
Performance. Autoneum tests
Quality
STJLR51.5341 /
personnel to
As specified in Annual Validation
acquire part(s) Raise NCR, inform Quality
Flammability CC 80mm/min Customer Every Year Schedule
and Manager
Specification
arrange testing
Pass / Fail
with accredited
source

Pack finished Each

Visual Re-pack complete batch in
Pack finished carpets in Production stillage of Packing
assessment 200% packaging specified by
parts designated Associates finished Instruction
during operation Packing Instructions
stillages parts
Stillage

Pack finished parts and raise Each

OP 80 Correct Visual check of Attach labels showing Part
stillage labels Customer Production stillage of Customer
identification for identification 100% No., quantity & delivery
Identification Associates finished specifications
shipment against parts destination
parts

Retain Form for Active Production Life + 1 Year

 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
11 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS Pack
PROCESS
finished/ parts
OPERATION
and raise JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
OP 80
NUMBER DESCRIPTION MANUFACTURE
stillage labels PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Label Containing Label Containing Each

Generate Correct Part Correct Part Production stillage of
Computer Std Ops 100% Std Ops Relabel as required.
Stillage ID Label Number, Quantity Number, Quantity Associates finished
and Date Etc. and Date Etc. parts

Retain Form for Active Production Life + 1 Year

 Issue Level Page
STK2734
Prototype Pre-Launch Production 16
12 of 12
Date: (Original) Issue Date
PRODUCTION CONTROL PLAN 08/04/2014 22/05/2019
Key Contact/Phone: Mick Turner01782645300 Supplier/Plant Approval/Date:
Part Name/Description: Part Number / Drawing No. / Latest Change Level:
HK72-130B28-AA* HK72-130B28-AA*
Main Floor Carpet Rear - 5 Seat Sliding (& Japan) HK72-130B28-BA* HK72-130B28-BA*
Main Floor Carpet Rear - 7 Seat Sliding (& Japan) HK72-130B28-CA* HK72-130B28-CA* UEB3 E 50151867 000
Main Floor Carpet Rear - 5 Seat Fixed (& Japan) HK72-130B28-DA* HK72-130B28-DA* 12/04/16
HK72-130B28-EA* HK72-130B28-EA*
HK72-130B28-FA* HK72-130B28-FA*
CHARACTERISTICS METHODS
MACHINE, DEVICE,
PROCESS PROCESS / OPERATION
JIG, TOOLS FOR CLASS SAMPLE REACTION PLAN
NUMBER DESCRIPTION MANUFACTURE PROCESS PRODUCT PRODUCT/PROCESS
RESPONSIBILITY EVALUATION CONTROL METHOD
PARAMETERS CHARACTERISTICS SPECIFICATION SIZE FREQ.

Parts Packed Stop Delivery

No Damage Each ADC Label Identify Condition
Correctly. As per customer
Visual stillage of ,Handling, Storage Isolate material
OP 90 Delivery Containers requirements / Logistics 100%
Correct assessment finished & Packing Hold for Disposition
Identified Purchase Order
Identification parts Procedure Verify Corrective Action
Correctly Complete Delivery

Retain Form for Active Production Life + 1 Year