Beruflich Dokumente
Kultur Dokumente
of Contents - 08/2010
General
1.2
1.3
General
2.2
2.3
Design Status
2.4
Recording Design
Revisions
General
3.2
Layout Format
3.3
3.4
Manual Design
Sheet Numbering
3.5
Detail Identification
General
4.2
4.3
General
5.2
Base Sizes
5.3
Base Machined
Tolerances
5.4
Line Blocks
5.5
5.6
1-3
General
6.2
Datums
6.3
Clamping
6.4
Gage PIns
6.5
6.6
Sight Checks
6.7
Hinge/Template Units
6.8
6.9
6.10
Material Specifications
6.11
Gage Colors
6.12
6.13
6.14
6.15
Verification of CMM
Inspection Data
7.2
Inspection
7.3
Certification
7.4
8.0 GR / GR&R
8.1
General
8.2
GR Study
8.3
GR&R Study
Buy-Off Form
9.2
10.0 SHIPPING
10.1
Transit
10.2
Packaging
10.3
Documentation
11.0 DEFINITIONS
2-3
12.2
12.3
APPENDICES
A.
B.
B2.
S0 Prototype Gages
C.
D.
S0 General Gages
E.
Meisterbock
3-3
REVISION
HISTORY
GEDOC001
Rev.13.1 8-2010
http://ame.ctc.chrysler.com
Revision:
Sec./Paragraph
Changed
Change Made:
Date:
Rev.13.1
8-2010
Section 7.3.4 D.
Changed point road map from upon request only to must be provided
7/29/2010
Section 12.1.1 A.
Add:
7/29/2010
Appendix E
7/29/2010
General Document
Section 1.1
1/04/2010
Section 2.1.5
1/04/2010
Section 4.1
1/04/2010
Section 4.3
Section 5.5.1
1/04/2010
Section 5.6.4
1/04/2010
Section 7.2.2 F.
1/04/2010
Section 8.2
m. GR Study - Update GR% to 6.0 multiplier for 99.73% across normal curve.
1/04/2010
Section 12.1.1 A.
1/04/2010
Section 12.2.1 B.
Add:
- Independence Tooling
- Lakeshore Fixture & Gauge
- Vendor Code = Tri-Star
Remove: - Sky-Tec LLC
- Ultimate Tooling
- US Gage
Use any Section 12.1.1 & 12.2.1 Design suppliers for design only.
1/04/2010
Section 12.3.1 C.
Add:
- Dynamic Metrology Services
Remove: - RCO Engineering
- US Gage
Update: - Metrology South Inc.
- Vendor Code + address = Valeo Climate Control
1/04/2010
General Document
Section 12.1.1 A.
7/06/2009
7/06/2009
Rev.13.0
1-2010
Section 12.2.2 B.
Rev.12.1
7-2009
Section 12.2.1 B
Section 12.2.2 B
1-2
All Rights Reserved
1/04/2010
1/04/2010
7/06/2009
7/06/2009
Revision History
8/01/2010
REVISION
HISTORY
GEDOC001
Rev.13.1 8-2010
http://ame.ctc.chrysler.com
Rev.12.0
1-2009
Section 12.3.1 C.
7/06/2009
General Document
Section 12.1.1 A.
Section 12.2.1 B.
1/05/2009
1/05/2009
1/05/2009
Section 12.2.2 B.
Section 12.3.1 C.
2-2
All Rights Reserved
1/05/2009
1/05/2009
Revision History
8/01/2010
Audience
General Overview
8/01/2010.
It is recommended to use the corporate standard Internet Explorer for intraChrysler access.
For content questions please contact:
Bill Bielby at (248) 576-0775 {Tie Line 776-0775]
Email: mailto:WRB2@Chrysler.com
Chrysler Contacts
1 2 3 4 5 6 7 8 9 10 11 12 Appendix A B B2 C D E
These links will launch a new Internet window.
Refer back to this page to navigate.
1-1
All Users
From:
Phone:
Email:
1.1 GENERAL
This standard provides a common gage standard used by all Chrysler Engineering Departments except Power
Train Engineering. This standard supersedes previous releases of the AME Gage Standard (GED0C001) back to
Rev.9-98.
This standard gives the gage source guidance in the requirements for design, build, inspection and certification of
Chrysler gages to check all body-in-white, trim and chassis components. These Chrysler Gage Standards shall be
adhered to for ALL gage check fixtures.
Chrysler is supporting the Tooling and Equipment Supplement to QS-9000. Supplier must be third-party minimum
certified to either QS9000 TE Supplement or ISO9001:2000, unless otherwise agreed to by Chrysler in
writing. After December 15, 2006, third party certification for ISO9001:2000 will be required. Suppliers must
obtain ISO9001:2000 certification from a TS16949 approved registrar and auditor. A list of TS16949 approved
registrars is available at www.iatfglobaloversight.org. Supplier will provide evidence of the certification to
Chrysler upon request.
Deviations from these standards may be granted from the Chrysler Gage Process Engineer in writing and would
be included with the standard as part of a specification package. All quotations shall then state that the gage
fixture being quoted will be designed and built to the specification package and/or Chrysler Gage Standard.
Design approval shall not constitute a waiver or guarantee of responsibility for any gage purchased by
Chrysler. An approved gage design does not constitute a certified or functional gage.
The Advance Manufacturing Gage Process Engineer has lead responsibility for all Chrysler user run plant
gages. Appendix "A" defines the tasks required to design and build Outside Supplier Gages. The product
releasing engineer has lead responsibility for the tasks identified in the Appendix "A".
Only Chrysler APPROVED design/build sources shall be used, unless agreed upon by the Chrysler Gage
Process Engineer in writing using Waiver or Deviation request form from Chrysler Gage Process Engineer for
approval consideration.
=>For consideration to supply Chrysler Group gage fixtures, request copy of "Request for Recommended
Chrysler Gage Design / Build Source" document form:
Request to ADD Gage Source v07 6-04.xls,
from supplier's Chrysler Gage Process engineer contact for filing to initiate review process. Follow document's
"Req(uest) Procedure" file tab to complete.
For outside supplier gages, the Supplier shall notify the Chrysler Gage Process Engineer for authorization if he
wishes to use a design / build source that is not on the approved / recommended source list (Refer to Gage
Standard Section 12.0).
1-2
http://ame.ctc.chrysler.com
Internet Address:
https://gsp.extra.Chrysler.com/mfg/amedd/gages/index.htm
(Contact assigned Chrysler Gage Process Engineers for assistance.)
2-2
2.1.6
Chrysler Gage Process will conduct a design kick-off/line-up meeting with the gage manufacturer.
2.1.7
The design proposal shall have Chrysler approval at 40%, 90%, and 100% completion. The design source will
submit one set of design plots for this review. All gage designs shall be signed-off by Chrysler Gage Process
Engineer using the Gage Design Kick-off, Review, and Approval form (GEFM001xx).
2.1.8
a.) ASME: Preliminary Operation Description Sheets (ODS) are to be made available at the 90% design review
for approval by Chrysler ASME Gage Process engineer.
b.) AAME: Preliminary Automated Manufacturing Planning Sheets (AMPS) are created by Chrysler AAME Gage
Process engineer with AMPS release two (2) weeks prior to V1 build when GR&R reports have been completed &
passed using S2 metal for verification of clamping sequence.
2.1.9
The gage shall address all G, D, &T controls and "toleranced" surfaces as shown on the released part model.
2.1.10
Minimum material thickness shall be used for the gage design, construction and CMM programming.
2.1.11
Design Considerations:
A. Operator and maintenance personnel safety.
B. Simplicity in operator part loading without restrictions or interferences.
1-4
2-4
10% = Placed.
(Supplier has part information. Job has been started.)
40% = Design ready for review and approval.
(Job is laid out. Material is being ordered.)
90% = Design ready for final review (complete), buy-off, and ship to build source.
100%=Design complete including any build changes and archived at Chrysler.
2.3.3 New Model Planning Reporting Standards: (MEDOC001 xx)
Reporting standards are to reference New Model Planning (NMP) document (MEDOC001 xx) for uniform
reporting percentages on gage fixtures.
2.4 Recording Design Revision
2.4.1
Standard stock list sheet shall be the sheet used for all revisions. It shall indicate the latest revision, revision date,
and revision authority. The stock list shall accompany design to the build source.
2.4.2
All Revisions will be written clearly and completely. Write revisions per sub-models affected. (Reference Figure
2.2a.)
Example: Detail X Sub-model XXXXX Form revise; Hole relocated.
2.4.3
All designs shall be updated to include changes made during construction and noted in the change column.
2.4.4
Gage design or construction changes are not to be made without Chrysler Gage Process Engineer authorization.
If changes are required after the GR / GR&R study is completed, the ODS shall be updated prior to shipment of
gage fixture to the user run plant.
2.4.5
Design revision Change Letters:
- First change letter used is "A".
- All following change letters are used consecutively.
- No change letter shall be skipped, except the letters "I", "O" and "Q".
- Design revisions will carry a common change letter on every sheet involved in a particular revision.
3-4
2.4.6 Changes shall reference the manufacturing Change Notice (CN) number and part engineering change
(EC) level.
4-4
1-3
3.2.10
Centerline and body lines shall be shown in three planes and in all views and sections. To front "O" line, to
centerline of body and to bottom "O" line.
3.2.11
Start dimensions shall be shown in three planes; in full metric dimensions, at the right lower side of plan view for
right hand fixtures, and left lower side of plan view for left hand fixtures.
3.2.12
The stock list shall list stock size, not name of detail, except for weldments, which shall be listed as "welded
construction". Note: Always use standard manufactured stock sizes.
3.3 Manual Design Sections
3.3.1
The gage design shall show plan, front, end views and all other views and sections necessary to clarify design.
3.3.2
On drawings requiring sections, start with section letter "A" and continue through the alphabet in order.
Exceptions shall be for the letters "I", "O", and "Q". Also, list the sheet number where the section can be found.
On the sheet with the section, indicate where the section is taken from.
3.3.3
All sections shall be full size or larger and noted. Any section that shows sheet metal shall be identified by part
number.
3.3.4
All sections shall be cut normal to part surface.
3.4 Manual Design - Sheet Numbering
3.4.1
Sheet Numbers & Type of Drawings:
Sheet #1 - Key sheet or layout sheet.
Sheet #2 - Stock list (standard form)
- Sheet #2a, 2b, 2c, etc. = Stock list continuation sheets.
Sheet #3 - Additional layout or detail sheets.
3.4.2
Numbering for unitized drawings:
Sheet 101 ( unit 1, sheet 1) General Layout.
Sheet 102 (unit 1, sheet 2) General Layout or detail.
Sheet 103 (unit 1, sheet 3) Bill of Materials (if required).
Sheet 104 (unit 1, sheet 4) and higher as required.
Sheet 1401 (unit 14, sheet 1) example of unit 14.
Sheet 1401 (unit 14, detail #14001, unit 1, detail #1001).
GEDOC001 Rev.13.1 8-2010
Copyright 2010 Chrysler Group LLC
2-3
Detail 17-BRACKET
(NORM)
1 REQUIRED SAE
1018
1 REQUIRED SAE
1018
WELDED CONSTRUCTION
WELDED
CONSTRUCTION
SYMMETRICALLY OPPOSITE
FOR LH
FIXTURE
AS SHOWN
FOR RH FIXTURE
Detail 28-BRACKET
(NORM)
1 REQUIRED SAE
1018
1 REQUIRED SAE
1018
WELDED
CONSTRUCTION
FOR RH FIXTURE
ONLY
WELDED CONSTRUCTION
FOR LH FIXTURE ONLY
-RH
etail 35-BRACKET
(NORM)
Detail 36-BRACKET
(NORM)
1 REQUIRED SAE1018
1 REQUIRED SAE
1018
WELDED
CONSTRUCTION
AS SHOWN
FOR RH SIDE
WELDED
CONSTRUCTION
SYMMETRICALLY
OPPOSITE FOR LH
SIDE
3-3
1-5
Figure 4.1 Design Circle Color Code reference for hole attributes.
Hole
TYPE mm
DWL - SF
DWL - PF
TAP
THRU / CLNC
SIZE/COLOR
RED (2)
PINK (95)
GREEN (3)
BLUE (4)
3R
3R
3R
3.5 R
4R
4R
4R
4.5 R
10
5R
5R
5R
5.5 R
12
6R
6R
6R
7R
16
8R
8R
8R
9R
20
10 R
10 R
10 R
11 R
GREY (10)
4.1.12
For wire frame designs, provide face definitions for periphery, flush, feeler, and net surfaces.
4.1.13
The gage shall be designed for N/C machining and shall be able to maintain dimensional integrity while being
machined.
4.2 CAD File Format for users
4.2.1
2-5
Example #1: The file name for an inspection model is given as: S7FTAN55255516AA_AR_S01R_REL.
The file name is defined as:
S = Stamping Tool Gage.
7 = Model Year of product; 1997.
FT = Flexible Tool Gage.
AN = Body style.
55255516AA = Part number.
AR = Product change level, "AR".
SO1R = Sub-model S01 Right Hand.
REL = Gage design change level "Release."
Example #2: The file name for an inspection model is given as: A7QRS3400_REL_S01_A
The file name is defined as:
A = Assembly Tool
7 = Cube Tool for 1997 RS
Q = Cube Tool fixture.
RS = Body style.
3400 = Area number.
REL = Product Change Level Release
S01 = Sub model S01
A = Tool design Change Level, "A".
4.2.2
When CATIA CAD designs are created for Chrysler checking fixtures, creation of symmetrically opposite
models is not required. The following guidelines are examples for symmetrical and asymmetrical fixtures.
Example #1: R1 Stamping Fixture for Panel Door Inner which is right hand shown, left hand symmetrically
opposite.
Part Info for Example #1:
Part #55251234AA Rt. Engineering Change Level "D"
Part #55251235AA Lt. Design Change Level "REL"
MY/VF 1998 DN
Only models for the right hand fixture are required.
The file name should contain both right hand and left hand part numbers. "RL" should follow the base and submodel identification, which designate the model as being right hand shown with the left hand symmetrically
opposite.
S8RDN55251234-5AA_D_STKLIST_REL
S8RDN55251234-5AA_D_R1ODS_REL
S8RDN55251234-5AA_D_BASERL_REL
S8RDN55251234-5AA_D_S01RL_REL
GEDOC001 Rev.13.1 8-2010
Copyright 2010 Chrysler Group LLC
3-5
Example #2: R1 Stamping Fixture for Panel Rear Qtr. Otr. which is right hand shown, left hand symmetrically
opposite except as shown.
Part Info for Example #2:
Part #55255678AA Rt. Engineering Change Level "C"
Part #55255679AA Lt. Design Change Level "REL"
MY/VF 1998 DN
All models for the right hand fixture are required.
Only non- symmetrically opposite models are required for the left hand fixture.
The filename should contain both right hand and left hand part numbers. "RL" should follow the sub-model
identification, which designate the model as being right hand shown with the left hand symmetrically opposite. "R"
should follow the sub-model identification, which designates the model as being right hand only. "L" should follow
the sub-model identification, which designates the model as being left hand only. The base sub-model should be
followed with the appropriate designation of "RL", "R" or "L".
Note: The left hand model should be created on the left hand side.
S8RDN55255678-9AA_C_STKLIST_REL
S8RDN55255678-9AA_C_R1ODS_REL
S8RDN55255678-9AA_C_BASERL_REL
S8RDN55255678-9AA_C_S01RL_REL
S8RDN55255678-9AA_C_S02R_REL
S8RDN55255678-9AA_C_S02L_REL
Example #3: R1 Stamping Fixture for Panel Cowl Side which is right hand shown, and left hand is significantly
different to justify a separate design.
Part Info for Example #3:
Part #55253456AA Rt. Engineering Change Level "C"
Part #55253457AA Lt. Design Change Level "REL"
MY/VF 1998 DN
All models for the right hand fixture are required.
Filename should contain only the right hand part number for the right hand part. "R" should follow the base and
sub-model identification, which designates the model as being right hand only. Filename should contain only the
left hand part number for the left hand part. "L" should follow the base and sub-model identification, which
designates the model as being left hand only. Note: The left hand model should be created on the left hand side.
Both designs require their own stock list and Operational Description Sheet (ODS).
S8RDN55253456AA_C_STKLIST_REL
S8RDN55253456AA_C_R1ODS_REL
S8RDN55253456AA_C_BASER_REL
S8RDN55253456AA_C_S01R_REL
S8RDN55253456AA_C_S02R_REL
S8RDN55253457AA_C_STKLIST_REL
S8RDN55253457AA_C_R1ODS_REL
S8RDN55253457AA_C_BASEL_REL
S8RDN55253457AA_C_S01L_REL
S8RDN55253457AA_C_S02L_REL
GEDOC001 Rev.13.1 8-2010
Copyright 2010 Chrysler Group LLC
4-5
Example #4: R1 Stamping Fixture for Panel Hood Inner which is right hand side shown, left hand side
symmetrically opposite.
Part Info for Example #4:
Part #55259876AA Engineering Change Level "D"
MY/VF 1998 DN Design Change Level "REL"
Only models for the right hand side of fixture are required.
"RL" should follow the sub-model identification, which designate the model as being right hand shown with the left
hand symmetrically opposite. "R" should follow the sub-model identification, which designates the model as being
right hand only. "L" should follow the sub-model identification, which designates the model as being left hand only.
No letter designation is required for base or sub-models which are a center line models.
S8RDN55259876AA_D_STKLIST_REL
S8RDN55259876AA_D_R1ODS_REL
S8RDN55259876AA_D_BASE_REL
S8RDN55259876AA_D_S01RL_REL
S8RDN55259876AA_D_S02R_REL
S8RDN55259876AA_D_S02R_REL
S8RDN55259876AA_D_S03_D_REL
Example #5: R1 Stamping Fixture for Panel Dash which is non-symmetrical across centerline.
Part Info for Example #5:
Part #55255432AA Engineering Change Level "D"
MY/VF 1998 DN Design Change Level "REL"
All models of the fixture are required.
No letter designation is required for base or sub-models.
S8RDN55255432AA_D_STKLIST_REL
S8RDN55255432AA_D_R1ODS_REL
S8RDN55255432AA_D_BASE_REL
S8RDN55255432AA_D_S01_REL
S8RDN55255432AA_D_S02_REL
4.3 CAD File Format (See 4.2.)
4.3.1 (Combined with 4.2 for 1/04/2010 release.)
5-5
1-8
5.1.14
All bases shall be machined on two adjacent edges.
5.1.15
All steel bases / frames shall be stress relieved
5.1.16
All aluminum bases shall be normalized.
5.1.17
Body Lines shall be scribed and stamped from finish adjacent edges of base.
5.2 Base / Frame Sizes:
5.2.1 Base material, size, and fabrication requirements.
Aluminum
Steel
6.0 in x
6.0 in to
6.0 in x
12.0 in
12.0 in x
8.0 in to
12.0 in x
16.0 in
18.0 in x
12.0 in to
18.0 in x
18.0 in
24.0 in x
24.0 in to
24.0 in x
36.0 in
18.0 in x
18.0 in to
48.0 in x
48.0 in
Aluminum Casting
30.0 in x
36.0 in to
30.0 in x
42.0 in
18.0 in x
30.0 in
36.0 in x
42.0 in to
36.0 in x
48.0 in
2-8
48.0 in x
48.0 in to
48.0 in x
84.0 in
48.0 in x
84.0 in to
48.0 in x
120.0 in
48.0 in x
120. 0 in
and over
3-8
4-8
5-8
6-8
3/4 TYP.
3/4 TYP.
7-8
8-8
No shims or adjustability shall be allowed in any gage. Chrysler Gage Process Engineer approval
required for the use of grind spacers.
6.1.3
All units mounted directly to a fixture base shall be built using dowel hole construction. Dowel at assembly is
permitted on the details / units that are indirectly mounted to the base.
6.1.4
6.0 mm diameter dowels shall be used unless dictated by a purchased component's dowel requirements.
6.1.5
Adequate protective safety devices shall be provided for protection of personnel and equipment, including stops
for drop assemblies and clamps.
6.1.6
Provide every gage with a gage certification tag (84-206-0020) supplied by Chrysler Gage Process Engineer.
(Figure 6.1c)
1 - 29
= Flush Check
FLUSH CHECK
CAD/CAM
MT =
Flush Check
Plus Metal Thickness
DESIGN SIDE
FLUSH CHECK
CAD
CAM
DESIGN SIDE
CAM
CL
CAD
DESIGN SIDE
FEELER CHECK
MT =
CL
MT =
CAM
CAD
DESIGN SIDE
& C
2 - 29
CAD/CAM
= Net Surface
NET
DESIGN SIDE
MT =
Net Surface
Plus Metal Thickness
CAD
NET
DESIGN SIDE
CAM
CAD
SIGHT CHECK
DESIGN SIDE
3mm CLEAR
CAM
MT =
CAD
SIGHT CHECK
DESIGN SIDE
3mm CLEAR
CAM
SD
= Shown Depth
(May be used with any symbol)
CAD/CAM
SHOWN DEPTH
3mm CLEAR
3 - 29
GAGE NO.
YR/VEH
PART NO.
PART NAME
RUN PLANT
BUILD SOURCE
ALSO CHECKS
NIC
E/C
DATE
CERTIFIED BY
INSP.DATA VERIFIED
GAGE CERTIFICATION
NIC
E/C
DATE
NIC
CERTIFIED BY
E/C
DATE
CERTIFIED BY
84-206-0020
GAGE NO.
E/C
DATE
CERTIFIED BY
GAGE REPEATABILITY
(GR) PASSED
GAGE REPEATABILITY &
REPRODUCIBILITY
(GR&R) PASSED
84-206-0021
4 - 29
6.2 Datums
6.2.1
The datums as indicated in the part model G, D & T sheet shall be utilized as locators. (Ref: Design Kick-Off
Form, GEFM001 xx).
6.2.2
Identify locating points; i.e. datum, locating holes or surfaces; as shown in CAD model & on operation description
sheets.
6.2.3
All 2-way and 4-way PLP locating stab pins will be made to MMC condition unless otherwise directed by Chrysler
Gage Process Engineer.
Note: A 2-way locating Pin going into a round hole should be able to slide in the non-locating direction.
6.2.4
All datum pads shall be made the same size as shown in G, D & T.
6.3 Clamping
6.3.1
All clamping units must have ergonomic handles to eliminate pinch points and be approved by Chrysler Gage
Process Engineer.
6.3.2
Clamp units are to be mounted to the fixture base. Do not mount clamps to fixture plank material.
6.3.3
All toggle clamping shall be 90 degrees to surface of metal.
6.3.4
All clamps shall be inside the edge of base when in the open position. To minimize base size, if clamp does
overhang base in full open position, provide a stop pin.
6.3.5
The clamp contact point shall be centered to the net block.
6.3.6
Dowel all clamps, especially the clamping on non-planer surfaces requires dowels.
Chrysler Gage Process Engineer to determine product necessity and functional requirements for dowel
elimination at time of design review.
6.3.7
Stops shall be added when required to prevent pinch points.
6.3.8
All clamps and movable units shall be shown in open and closed position. Arc of travel and clearance to adjacent
units shall also be indicated. (Figure 6.3a)
5 - 29
SINGLE NET
DUAL NET
INSIDE CORNER
DUAL NET
OUTSIDE CORNER
6 - 29
7 - 29
CARR LANE
GAGE HANDLE
SIZED TO SELECTED
GAGE HANDLE
A
1.5 x 45
BOTH ENDS
17.0
19.0
G
G
RECEIVER BUSHING
19.0
SIZED TO SELECTED
RECEIVER BUSHING
10.00
-.25
9.75
-1.00
8.75
Hole diameter.
Minus minimum tol of hole size.
= Maximum material condition (Lo Limit of Hole)
Minus hole location toerlance.
= Gage pin diameter 'A'
For pierce and weld nuts. Use appropriate internal minor diameter listed in chart below
and subtract location tolerance to obtain gage pin diamter 'A'.
NUT SIZE
M5 X 0.8 - 6H
M6 X 1.0 - 6H
M8 X 1.25 - 6H
M10 X 1.5 - 6H
M12 X 1.75 - 6H
8 - 29
6.4.6
For a threaded hole pin, use minor diameter of thread minus ""locational"" tolerance for the pin size. Length of pin
shall be equal to projected tolerance zone specified on the part model G, D & T sheet.
6.4.7
See Figure 6.4c for construction information when using a double ended stab pin as a datum locator.
6.4.8
All blind hole checks shall have scribe pin capability. (Figure 6.4d)
6.4.9
All gage pins shall slip fit into standard size bushings. Bushings shall be press fit in nominal position in the gage.
Lock-Tite shall not be used.
9 - 29
36.0
19.0
GO PIN
NO-GO PIN
G
CARR LANE
GAGE HANDLE
ROUND +TOL.
G
G
CARR LANE
GAGE HANDLE
STEPPED
GO/NO-GO PIN
SAE OIL HARDEN
& GRIND R/c 58-60
GO PIN
36.0
19.0
G
ROUND -TOL.
NO-GO PIN
CARR LANE
GAGE HANDLE
SHAPED +TOL.
10.00 0.05
10 - 29
1.5 x 45
BOTH ENDS
1.5 x 45
BOTH ENDS
17.0
61.0
25.0
G
G
19.0
G
G
19.0
D or E
A S.F.
A S.F.
15 INCL.
FOR GAGE
GAGE HOLE
9.00
13.00
19.00
25.00
HOLES
A
.250
.250
.250
.375
G
7.0
4.0
3.0
1.5
11 - 29
CARR LANE
GAGE HANDLE
SIZED TO SELECTED
GAGE HANDLE
SIZED TO SELECTED
RECEIVER BUSHING
SCRIBE PIN
1.5 X 45
RECEIVER BUSHING
30
40.0
19.0
75.0
SAE OIL HARDEN
& GRIND R/c 58-60
LEAVE SHARP
'A'
10.00
-.25
9.75
-1.00
8.75
Hole diameter.
Minus minimum tol of hole size.
= Maximum material condition (Lo Limit of Hole)
Minus hole location toerlance.
= Scribe pin diameter 'A'
12 - 29
GRADUATION SET
62.0
GAGE HANDLE
5.0
40.0
20.0
STUD CHECK PIN
DIA. B TO SUIT
CLEARANCE HOLE
A
STUD CHECK PIN
SAE OIL HARDEN & GRIND Rc 58-60
D = GAGE HANDLE COLLET DIA.
STUD SIZE
M5 X 0.8 - 6G
M6 X 1.0 - 6G
M8 X 1.25 - 6G
M10 X 1.5 - 6G
M12 X 1.75 - 6G
MAJOR DIA. A
4.976
5.974
7.972
9.968
11.966
13 - 29
RECOMMENDED GAGE HANDLE S & BUSHINGS FOR GAGE HOLE LOCATING PINS
CARR LANE
GAGE HANDLE
MMC CONDITION
RFS CONDITION
GAGE
HOLE
CARR LANE
HANDLE
CARR LANE
HANDLE BUSHING
(2 REQ'D)
9.00
13.00
19.00
25.00
CL-4-GHD
CL-4-GHD
CL-4-GHD
CL-6-GHD
CL-4W-321
CL-4W-321
CL-4W-321
CL-6W-563
CARR LANE
RECIEVER BUSHING
P-26-12
P-26-12
P-26-12
P-40-12
CARR LANE
GAGE HANDLE
RFS CONDITION
MMC CONDITION
GAGE
HOLE
CARR LANE
HANDLE
CARR LANE
HANDLE BUSHING
(1 REQ'D)
9.00
13.00
19.00
25.00
CL-4-GHS
CL-4-GHS
CL-4-GHS
CL-6-GHS
CL-4W-321
CL-4W-321
CL-4W-321
CL-6W-563
CARR LANE
RECIEVER BUSHING
P-26-12
P-26-12
P-26-12
P-40-12
14 - 29
15 - 29
INCORRECT SURFACE.
DO NOT FOLLOW MATING PART.
CORRECT SURFACE.
0 EXTENSION TO
CHECKED SURFACE.
90
GAGE BAR
PANEL - FENDER OUTER
90
GAGE BAR
20.0 TYP.
FEELER CHECK
GAGE BAR
16 - 29
17 - 29
18 - 29
6.8.4
Fastening cables and / or a storage box shall be provided as required for all loose details when not in use on the
gage.
6.9 Statistical Process Checks
6.9.1
All critical characteristics require variable data gathering capability, unless specified by Chrysler Gage Process
Engineer.
6.9.2
Identify numerically all transducer points in operation description sheets with tags on the gage.
6.9.3
SPC bushings shall be set to math data.
6.9.4
SPC bushings shall have heads, be press fit, and not threaded. (Figure6.9a)
6.9.5
Adequate protection must be provided for all fixture mounted transducers.
6.9.6
The (2 in 1) flush and gap transducer should be used for design clearance conditions.
6.9.7
LMI flush and feeler blocks shall be mounted normal/parallel to all features checked. (Figure 6.9a)
19 - 29
LMI 200-S
PROBE TRANSDUCER
31.00
SET-UP
24.00
FLUSH CHECK
POINT
FLUSH CHECK
ON RAIL
HOOD ASSY
LMI 776 MTG
BLOCK
GAGE BAR
19.00 SET-UP
CENTER OF
LOCATING DOW EL
20 - 29
Base and raw aluminum components, Black anodized or color, to be determined by Gage Process
engineer for multiple models used in cross loading of assembly plants.
Standard hard aluminum risers, etc., may remain coated as received and will not be required to be
painted light blue.
21 - 29
6.11.3
Black oxide all steel check details; i.e. nets, pins. All lettering on black oxide details shall be white.
6.11.4
Paint all non-check elements on hand apply fixtures light blue, NPVP 2.5 PB 7/6; Chrysler commodity code #65153-4770.
6.11.5
Consult AME0010 Chrysler Color Identification of Capital Equipment, Dies, Fixtures, Tools, and Machinery
document for paint series identification requirements. Document available through Gage Process Engineer.
6.11.6
For painting of welded clamp handles REFERENCE document AME0010 Chrysler Color Identification of
Capital Equipment, Dies, Fixtures, Tools, and Machinery available through Gage Process Engineer..
6.11.7
For painting of sight check holes REFERENCE document AME0010 Chrysler Color Identification of Capital
Equipment, Dies, Fixtures, Tools, and Machinery available through Gage Process Engineer. .
6.11.8
For painting of feeler checks REFERENCE document AME0010 Chrysler Color Identification of Capital
Equipment, Dies, Fixtures, Tools, and Machinery available through Gage Process Engineer.
6.11.9
The gage construction source will be responsible for filling out the Chrysler supplier regulated substance
certification report form, ETI-103, for their program fixtures requiring compliance. (See Chrysler Gage Process
Engineer for documentation.)
6.12 Gage Stamp Requirements
6.12.1
Gages that check different assemblies and details shall clearly identify the interchangeability for each part.
Stamp the part number clearly and paint with the proper color identification code.
6.12.2
Stamp datum surface identification on fixtures and on N.C. blocks.
6.12.3
Stamp as indicated by the gage design, feeler, flush, and clearance on sight checks.
6.12.4
Stamp body coordinates of start dimensions on base surfaces.
6.12.5
Stamp gage pin diameter, detail number and tool number on all gage pins.
6.12.6
Stamp tool number, detail number and sub-model number on all details.
22 - 29
6.13.1
The part shall fit within the envelope of the CMM machine with enough clearance for the CMM machine to reach
any point with a part loaded. Measurement head configuration and CMM parameters shall be provided by the
user run plant.
6.13.2
Maximum weight for holding fixtures shall be determined by the user run plant.
6.14 Operation Description Sheets (ODS)
6.14.1
Operation Description Sheets describe the initial set-up of checking fixture, the loading of the part, the sequence
of clamping operation and clear instructions for all feature inspections. (See Figure 6.18 a,b,c,d). Chrysler Gage
Process Engineer to provide CAD model example of ODS sheets.)
6.14.2
The ODS sheets created in AMPS by Chrysler AME / BIW will follow the gage standard format in section 6.14. In
Chrysler ASME, ODS templates and specifications will be referenced as a supplement to section 6.14 of the gage
standards.
6.14.3
The clamping sequence shown in the operation description sheets will be determined at the 40% design review
and updated after a successful GR&R study. This sequence will be labeled on the fixture with tags attached to the
clamp or the clamp units.
6.14.4
All transducer checks, with their SPC check sequence number, and the X,Y, Z nominal coordinate of the
checkpoint will be shown. Include any engineering identification number or letter, if any. (i.e."M" points.)
6.14.5
Usage of any removable details will be clarified, storage must be provided & labeled.
6.14.6
The last page of operation description sheets (ODS) package will be a Pin chart showing detail number, Hole
Size, Hole Size Tolerance, pin size, and pin usage. This chart will include PLP pins, Go/NoGo pins, Scribe pins,
and Feeler Gages.
6.14.7
The ODS shall be plastic laminated and attached to the base of fixture.
23 - 29
24 - 29
25 - 29
26 - 29
27 - 29
6.15.4
When a dual arm CMM is being used, five (5) tooling balls or head press fit metric bushings with covers are
required; two (2) for each arm and one (1) to be shared by both arms. (Figure 6.15a)
ARM 2
ARM 1
28 - 29
TOOLING BALLS
TOOLING BALL
E&E EEM-12-SCB ( 12.0mm )
TOP OF BASE
29 - 29
1-5
E. Sight Check (irregular shaped hole) - make one (1) row of data; 3mm from top surface.
F. Sight Check (round or slot holes) - make one (1) row of data; 3mm from top surface to check size and location,
if it's a slot check the angle. Project check nominal to part surface.
G. Plug Check (round or slotted holes) - make two (2) depths of cylinder check points to determine size and
location. Check the angle normal to surface if it's a slot, check the angle. Project check nominal to surface.
H. All fixture features inspected MUST be clearly identified in the gage inspection report.
Page 1 - 3
1-05-2004
NOMINAL
UNITS=MM
MEAS
+ TOL
- TOL
DEV
1993.330
1993.514
0.200
0.200
0.184
0.000
902.520
902.494
0.200
0.200
-0.026
0.000
1140.530
1140.670
0.200
0.200
0.140
0.000
5.250
5.274
0.200
0.200
0.024
OUTTOL
0.000
7.3 Certification
7.3.1
The gage must be certified prior to performing GR&R and buy-off for shipping to the user run plant.
7.3.2
(Eliminated, 10/2002, by Chrysler Gage committee.)
7.3.3
The inspector will certify that the gage has been built dimensionally correct within the acceptable tolerances.
2-5
7.3.4
Supplier shall have available for the Chrysler Gage Process Engineer the following items:
A. An approved gage design and stock list.
B. Verification of the CMM inspection program.
C. Inspection data.
D. A road map showing the location of the inspection points must be provided.
E. Latest product model, including math data and G, D&T.
F. The program Chrysler Gage Design and Build Standards.
7.3.5
Upon completion of an approved certification, the certification tag will be stamped with supplier's/construction
stamp next to the latest engineering change. This stamp indicates that the gage has been certified to the
inspection data and has met the dimensional requirements.
7.3.6
The certified inspection data will be sent via electronic format to the Chrysler's CATIA file. Certification data will be
stored with gage design.
7.3.7
The certification inspection data and the road map will be included in the gage history book and shipped with the
gage. (Refer to Gage Standards Section 10.0 Shipping.)
3-5
Location
Size
Locating Pins
+/- 0.05mm
+0.0 /0.02mm
Net Surface
Surface
+/- 0.05mm
+/-1.0mm
Flush Check
+/-0.15mm
3.0mm Feeler
Check
+/-0.12mm
3.0mm Clear
+/-0.25mm
Pin Checks
+/- 0.10mm
+0.0/ 0.02mm
Go Pin
+0.0/ 0.02mm
No Go Pin
+0.02/ 0.0mm
Sight Checks
+/- 0.20mm
SPC
Transducer
Bushing
+/- 0.05mm
Normal to
Surface
+/-0.50mm
SPC Flush
and Feeler
Block
+/- 0.05mm
Normal to
Surface
+/-0.50mm
Drilled and/or
Tapped
+/- 0.13mm
Dowel Holes
for items
mounted to
Fixture Base
+/0.013mm
Units or SubBases to be
held
+/-0.05mm
from Start
Fixture Base
+/0.12
4-5
Location
Size
Surface
+/-0.125mm
+/- 0.20mm
(2) Nets or
more on (1)
unit
+/-0.125mm
& +/-0.05mm
to each other
Flat Form
Net
+/- 0.125mm
Locating Pins
+/- 0.125mm
Final
Machine
Placement of
Module
+/- 0.10mm
+/-0.05mm
Flatness
+0.0/-.02mm
5-5
1-3
m.) After data has been collected, input measured results into GR worksheet in GEFM010xx. To calculate GR
study results. If GR worksheet in GEFM010xx is not available, use the following table and formulas to calculate
GR study results:
( X X )2
1
2
3
4
5
6
7
8
9
10
Tot
GR % =
MR
=
d2
( X X )2
6.00
n 1
/ Tolerance 100 =
0.972
n.) Resulting values that are considered passing values for a GR study are as follows:
1. Under 20% error is required for critical product characteristics.
2. 20% to 30% error may be acceptable based upon the importance of the application; i.e. non-critical product
characteristics, cost of gage, cost of repair, etc. Acceptability shall be determined by the Chrysler Gage Process
Engineer.
3. Over 30% error, the measurement system needs improvement. Identify the problems and have them
corrected.
8.3 GR&R Study:
a.) Fixture must be inspected and certified prior to performing GR&R study.
b.) To perform a GR&R study, five (5) parts / assemblies and two (2) operators are required.
c.) A complete GR&R study requires that each part/assembly is loaded, measured and unloaded twice. Operator
A will randomly load each part / assembly once. Operator B will load each part / assembly once in the same
order as Operator A. (5-2-1 Method)
d.) Pre-determined points will be measured each time the part / assembly is loaded. Method of data collection
may be done either by CMM machine or hand held electronic data collector. Laser or Vision System
measurement devices may be used only if approved by the Chrysler Gage Process Engineer.
2-3
e.) Steps f.) through k.) are to be repeated once for each of the five (5) times Operator A loads / unloads a
part / assembly and once for each of the five (5) times Operator B loads / unloads the same part /
assembly. (5-2-1 Method)
f.) Ensure that the fixture is set-up in accordance with the ODS / AMPS for the part / assembly that is being
measured.
g.) Operator loads part / assembly into fixture according to ODS / AMPS.
h.) Measure pre-determined points.
k.) Operator unloads part/assembly.
m.) After data has been collected, input measured results into GR&R worksheet in GEFM010xx to calculate
GR&R study results. If GR&R worksheet in GEFM010xx is not available, use the following table and formulas to
calculate GR&R study results.
Part
1
2
3
4
5
Sum of Ranges
AverageRange ( R ) =
R =
5
GRR as a % of Tolerance =
(GRR ) (100%)
=
Tolerance
100%
n.) Resulting values that are considered passing values for a GR&R study are as follows:
1. Under 20% error is required for critical product characteristics.
2. 20% to 30% error may be acceptable based upon the importance of the application; i.e. non-critical product
characteristics, cost of gage, cost of repair, etc. Acceptability shall be determined by the Chrysler Gage Process
Engineer.
3. Over 30% error, the measurement system needs improvement. Identify the problems and have them
corrected.
3-3
1-1
1-1
1-2
(G) GAGE: Template, plug gage, contour block or portable lightweight gage.
(H) GAGE: CMM holding fixture for CMM use. Fixture to hold part, panel or assembly for measurement on CMM.
LINEARITY: Accuracy of a gage over its measuring range.
LOCATORS: Check fixture features that locate the part datums relative to a known system (base, CMM etc.) for
the purpose of measuring the features of the part.
MANUFACTURING CHANGE NOTICE (MCN): A formal process for initiating, communicating and implementing
engineering changes.
MAXIMUM MATERIAL CONDITION (MMC): State or condition of a part when maximum material is present; (i.e.
holes at minimum size, part boundaries at maximum).
NON-CONTACT GAGING: A process for imaging product & features then converting a series of 2-dimensional
digital images into an accurate 3-dimensional representation and measurement data.
QUALITY: Fitness of part / assembly for use as measured by conformance to specifications and workmanship
standards compatible with customer expectations.
RELIABILITY: The probability that a gage will adequately perform its intended function, in customer use, at a
target time or interval.
REPEATABILITY: Variation in measurements from one operator using a gage several times to measure identical
characteristics on the same part.
REPRODUCIBILITY: Variations in average measurements from different operators using a gage several times to
measure identical characteristics on the same parts.
REGARDLESS OF FEATURE SIZE (RFS): The term used to indicate that a geometric tolerance or datum
reference applies at any increment of size of the feature within its size tolerance.
RMS (ROOT MEAN SQUARE - Rq): Method of calculating an average roughness value. This is obtained by
squaring each value and then taking the square root of the mean.
(R) GAGE: Attribute checking fixture qualified for production parts.
(S0) GAGE: Stamping soft-tool checking fixture.
SIGHT CHECK: Simplest visual method for verifying part features by pattern comparison. Normally this check is
used for non-critical features.
STABILITY: Variation of a gage's measurements over time.
TEMPLATES: Checking fixture details made from thin material to check localized part forms / features.
VARIABLE DATA: Quantitative data that specifies actual part measurements.
VERIFICATION: Confirmation of the certification data (inspection program) back to the CATIA model data. Third
party requirement for gages. Confirm that the gage is designed and built to the Chrysler Gage Standard.
VISION SYSTEMS: Cameras used for in-line process trend analysis.
GEDOC001 Rev.13.1 8-2010
Copyright 2010 Chrysler Group LLC
2-2
ADDRESS
PHONE NO.#
SUPPLIER
CODE NO.#
A.
FUTURAMIC
586-758-2200
586-497-8850
38454
A.
248-588-2393
53393
METRO
TECHNOLOGIES
Ltd.
248-528-9240
96145
A.
STANDARD
COMPONTENTS,
Inc.
586-323-9700
77457
A.
A.
SHARP MODEL
CO.
586-752-3099
52186
SMITH BROTHERS
TOOL
50600 Corporate
Drive Shelby Twp.,
MI 48315
586-726-5756
54537
A.
51455 Schoenherr
Road Shelby Twp.,
MI 48315
586-726-0000
40750
A.
SPEC
TECHNOLOGIES,
Inc.
List
Troy, MI 48083-1904
SECTION 12.1.1
NOTE: A. Any SECTION 12.1.1 A. supplier may also provide either Design or Build separately.
1-7
ADDRESS
PHONE NO.#
ADVANTAGE
DESIGN & TOOL,
Inc.
586-463-2800
(None)
B.
B.
ADVANTAGE
INDUSTRIES, Inc.
616-669-2400
(None)
ANSWER
PRECISION TOOL,
Inc.
519-748-00790
(None)
B.
APPLIED
COMPOSITES
ENGINEERING
317-243-4225
32264
B.
GLASS checking
fixtures, ONLY.
Design & Build.
B.
616-454-8266
(None)
ARCE TOOL
(011-52) 222261-0971
62060
Mexico Gages
ONLY. Design &
Build.
AUTOMOTIVE
GAGE
& FIXTURE
519-737-2922
(None)
519-737-7677
(None)
B.
664 Bishop
Street
Cambridge,
ON N3H 4V6
519-653-2977
(None)
B.
586-296-1103
(Shares
RCO#)
81097
B.
CLARK FIXTURE
Technology Mexico
S. de R.L de C.V.
844-490-5555
ext. 103
(None)
Mexico Gages
ONLY. Design &
Build.
List
B.
B.
B.
SUPPLIER
CODE NO.#
844-490-5557 (fax)
2-7
COMAU-PICO Pitex
S. de R.L. de C.V.
B.
58388
Mexico Gages
ONLY. Design &
Build.
CP 54610
COSTELLO
Enterprises
586-749-0136
(None)
CP INDUSTRIES
574-273-3000
49899
GLASS checking
fixtures ONLY.
Design & Build.
D & F CORP.
586-254-5300
30003
B.
EXPRESS GAUGE
42265 Yearego
Sterling Hgts., MI 48314
586-323-9800
(None)
29870
B.
FFT MEXICO
SA de C.V.
Mexico Gages
ONLY. Design &
Build.
B.
B.
B.
72226
GAGE PATTERN &
MODEL Inc.
32070 Townley
Madison Hgts., MI 48071
248-585-9352
24060
HERRAMIENTAS
Cuernavaca Morelos,
Mxico 62460
50521
Servicios Automotrices
S.A. de C.V. (HERSA)
Mexico Gages
ONLY. Design &
Build.
HI-TECH MOLD
ENGINEERING
248-852-6600
(None)
B.
INDEPENDENCE
Tooling
248-250-7715
(None)
B.
INSPECTION AIR
GAUGE Ltd.
519-966-1232
52094
B.
JAY-ENN
248-588-2393
53393
B.
586-726-6960
(None)
LAKESHORE
Fixture & Gauge
519-737-2635
(None)
Build
B.
B.
B.
B.
3-7
B.
LASARD
519 727-4009
(None)
MAGOVE
Prolongacion Miguel
Allende 11 Fracc. Ind.
Tultitlan
Estado
(011-52) 555888-0028
61054
Mexico Gages
ONLY. Design &
Build.
B.
de Mxico 54900
B.
METROCAL, Inc.
616-698-3124
(None)
B.
MP COMPONENTS
Inc.
616-878-9710
(None)
B.
MP COMPONENTS
Inc.
800-456-4509
931-525-1600
(None)
B.
616-866-8296
(None)
B.
45 Cox Drive
Gilbertsville, KY 42004
270-362-4763
(None)
B.
586-759-0250
72578
B.
PROTOTYPE
SYSTEMS Inc.
586-795-3690
20907
B.
248-597-3984
24444
B.
RCO
ENGINEERING Inc.
29200 Calahan
Roseville, MI 48066
586-771-8400
81097
B.
519-737-6974
(None)
B.
ROMEO
TECHNOLOGIES
586-336-5015
50513
B.
SCHWAB
INDUSTRIES, Inc.
586-566-8090
33414
B.
SELECT TOOL
519-737-6406
(None)
734-454-0500
60017
B.
SUPERIOR
CONTROLS
Exhaust
component
check fixtures,
ONLY.
Cookeville, TN 38506
4-7
TRI-STAR
ENGINEERING
586-978-0435
66055
B.
519-737-9075
(None)
B.
TRI-TECH MODELS
& FIXTURES
B.
UNIQUE MODEL
Inc.
616-791-0966
(None)
VALIANT Machine
Tool & Gage
519-974-5200
36567
B.
ONLY
NOTE: Any SECTION 12.2.1 B. supplier may also provide either Design or Build separately.
SUPPLIER:
ADDRESS
List
PHONE NO.#
SUPPLIER
CODE
NO.#
5-7
C.
3C METROLOGY
S.A. de C.V.
555-514-0188
60689
Mexico Gages
ONLY.
Third Party Verify
ONLY.
ACCU-TECH
586-323-1181
(None)
BENTELER
Defesores De La
Republica N99
Aona Industrial Norte
C.P. 72260 Puebla,
Pue. Mxico
(011-52) 222-2232174
11959
Mexico Gages
ONLY.
Third Party Verify
ONLY.
CARL ZEISS
de Mxico S.A. de
C.V.
Miguel Angel de
Quevedo 496 Col. Sta
Catarina. Mxico
(011-52) 442-2290171
92988
Mexico Gages
ONLY.
Third Party Verify
ONLY.
CLARK FIXTURE
TECHNOLOGIES
(011-52) 844-4905555
(None)
Mexico Gages
ONLY.
Third Party Verify
ONLY.
COSTELLO
56358 Precision
Drive
Chesterfield Twp., MI
48051
586-615-6307
(None)
DYNAMIC
METROLOGY
Services
616-836-3524
(None)
GAGE CHEK -
32082 Townley
Madison Hgts, MI
48071
248-585-2476
24060
GESTAMP
(011-52) 722-1996743
60552
Mexico Gages
ONLY.
Third Party Verify
ONLY.
INSPECT X
5575 Roscon
Industrial Drive
Old Castle, ON N0R
IL0
519-737-2667
(None)
C.
C.
C.
C.
C.
C.
C.
C.
C.
Holland, MI
49424
6-7
C.
C.
C.
C.
C.
C.
METROLOGY
South, Inc.
205-280-1455
MICHIGAN
MEASUREMENT
SERVICES
248-577-1886
(None)
MICRO
PRECISION
METROLOGY
Inc.
2010 Fasan
Drive Oldcastle, ON
N0R 1LO
or
125 Turnbull Court
Unit#9 Cambridge, ON
NIT 1H8
519-737-9626
(None)
Third
Party
ONLY.
Verify
RT PRECISION
MEASUREMENT
Inc.
2679
Howard
Windsor,
ON N8X 3X2
519-969-7785
Third
Party
ONLY.
Verify
SPEC CHECK
51455 Schoenherr
Road Shelby Twp.,
MI 48315
586-726-0000
54779
SUPERIOR
MEASURING
1605 East
Avis
Madison
Hgts., MI 48071
248-616-4607
(None)
TSI INSPECTION
586-739-5203
(None)
Third Party
SUPPLIER Gages
ONLY.
ISO/IEC17025:1999
VALEO
Manzana 4 Lote 1
Parque Industrial
Exportec II
Toluca, Estado de
Mexico
C.P. 50200
(011-52) 722-2794000
ext 4086
14949
Mexico Gages
ONLY.
SPEC
TECHNOLOGIES, Inc.
C.
C.
(None)
Third
Party
ONLY.
90 Bama Lane
Clanton, AL
35045
205-280-0155 (fax)
Verify
519-621-7454
(None)
7-7
1-5
START Outside
Supplier Program
RESPONSIBILITY:
Product Supplier
Product Team
Product Supplier
Gage Engineer
Product Supplier
& Gage Engineer
A. Kick-Off
Gage Engineer
Gage Manufacturer
Product Supplier
6. Begin build
Product Supplier
Product Supplier
Gage Manufacturer
Product Team
Gage Engineer
Product Supplier
Gage Engineer
Gage Engineer
Gage Engineer
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APPENDIX A
OUTSIDE SUPPLIER GAGES
A.1 GENERAL
All "End Item" Parts require a gage designed & built to AME / ASME Gage Standards and be approved by the
Chrysler Product Team.
A.1.1 Product Team
The Chrysler Product Team consists of :
1. Product Releasing Engineer (Lead Engineer & Product Team Leader),
2. Product Supplier,
3. Gage Process Engineer,
4. Dimensional Control Engineer,
5. Supplier Quality Engineer .
The Product Team Leader may ask for other team members to participate, when appropriate.
A.1.2 Product Team tasks:
1.
2.
3.
4.
Product Supplier develops a Timing & Progress schedule for designing & building of gages and
documents issues, resolutions, etc., with meeting minutes.
The Product Team approves the datum scheme for the gage.
The Product supplier is to select a Gage Manufacturer from the recommended source list (Gage
Standards Chapter 12) to design / build the gage. If he wishes to select a gage source that is not on the
recommended list, he must first obtain written permission from the assigned Chrysler AME/ASME Gage
Process Engineer.
The Product Supplier is to schedule the following Gage design review meetings, inviting all team
members:
A. Kick-off Review
1. Discuss basic concept, GD&T, & Chrysler requirements.
(Note: This step may be omitted by the team.)
B. 40% Complete Review:
1.
2.
3.
4.
The design is to include all the necessary views & sections to show gage functionally.
The design is to incorporate all requirements within these Gage standards
All changes or additions the team requires to be made, are to be recorded on page 2 of the
design approval form by the Gage Process Engineer.
Chrysler AME/ASME Gage Process Engineer will issue the Gage Design Approval Form
(GEFM001), with a 40% design review sign-off.
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d. Part name.
e. Supplier Name.
f. Design & Build source name.
4.
5.
5.
6.
7.
8.
9.
A.
B.
C.
D.
Chrysler AME/ASME Gage Process Engineer to enter all information into the Chrysler fixture tracking
system "EnGage".
Gage manufacturer begins build NC cutting fixture to latest Product model.
Gage fixture supplier to create a CMM Inspection Program. (Ref. Gage Standard Chapter 7.)
Gage Manufacturer to certify gage on CMM. (Ref. Gage Standard Chapter 7.)
A. The gage must be dimensionally correct within the acceptable tolerances. (Ref. par. 7.4)
B. Provide surface I, J, K vectors.
C. Third part audit required upon Gage Process Engineer's request for data verification.
Gage fixture supplier to send Inspection Data to the Team Leader. Data must include:
Graphic that identifies all points checked.
Nominal dimension, measured dimension, deviation of each point, and surface I, J, K vectors.
Part Number.
Part Engineering Change (E/C) Level.
10. A designated team member (Chrysler Product Engineer, Dimensional Control Engineer or Gage Process
Engineer) will review the inspection data.
11. Gage fixture supplier performs Gage Repeatability & Reproducibility (GR&R) study.
A. Refer to Chapter 8.0 of GEDOC001 Gage Standards for GR&R intent.0 EXCEPTION 8.c.) &
8.e.). [
1. For APPENDIX A only, a complete GR&R study requires that each part/assembly is loaded,
measured and unloaded twice by both operators. (Operator A will randomly load each part / assembly
twice. Operator B will load each part / assembly twice in the same order as Operator A. (5-2-2 Method))
2. For APPENDIX A only, steps are repeated twice for each of the five (5) parts. (Operator A loads /
unloads a part / assembly twice and Operator B loads / unloads the same part / assembly twice for each
of the five (5) parts. (5-2-2 Method))
A. Team Members must witness the GR&R study.
(NOTE: A. If required number of parts for a GR&R are not available, then a Gage Repeatability (GR) study may be passed.)
B. Passing a GR does not relieve the gage fixture supplier from completing & passing a GR&R study,
if requested.
12. Gage fixture supplier to send GR / GR&R data to Team Leader. The GR&R study data must include:
A.
B.
C.
D.
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13. A designated team member (Product Engineer, Dimensional Control Engineer or Gage Process
Engineer) will review data.
(Note: Upon approval the Gage Process Engineer will issue a Chrysler GR&R Certification Tag, 84-2060021.)
14. Product Supplier to schedule a Gage Buy-Off meeting, inviting all team members.
Criteria for Buy-Off are:
A. Gage supplier to schedule Gage buy-off meeting at gage build source, inviting all team members.
B. The following items must be available prior to buy-off meeting:
1. Gage Record Book (or PSO book) with required documents.
(Ref. Gage Standard Appendix A. Item 14.)
2. Print of the gage design and stock list.
3. CATIA print of the latest product model.
15. Gage fixture supplier creates a Gage Record Book:
A.
B.
C.
D.
E.
F.
G.
H.
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B.1.
a.
b.
All soft/hard trim Gages to be constructed per current release of AME/ASME Gage Standards
and the following guidelines.
All supplierss to follow procedure's as outlined in Gage Standards Appendix A.
Datums
B.2.
b.
Functional datums (where mating part would support) can also be used (Per approval of the
Product Team. See Gage Standards Appendix A.)
All functional datums must be able to swing clear of part.
a.
b.
Swing templates simulating the mating part are to be used at all significant "Gap" areas.
Swing templates can also duplicate as functional datums.
a.
b.
c.
a.
Fixed scales may be used for collecting variable data. All variable data collecting devices must be
approved by the product team.
a.
b.
Grid lines are to be incorporated in all soft trim tub gages every 200mm (F/A direction only).
Grid Lines are to be used for reference only.
a.
Swing Templates
B.3.
Materials
B.4.
B.5.
Grid Lines
B.6.
Tolerancing
B.7.
Tolerance on all net surfaces shall be +/-0.05; all other fixture details will be +/- 10% of the parts
smallest tolerance of the area being checked.
b. A tolerance band representing the inner most and outer most dimensions of periphery of part is to
be NC machined approximately 1mm deep in all fixtures and painted GREEN.
a.
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A machined sight check is required for all non-critical holes, slots, and cut outs. A stab pin is required for all
critical holes. A scribe pin and bushing may also be acceptable to check critical holes with approval of the
Chrysler Dimensional Control Team.
A Go/ NoGo pin check is required to check all PLP and datum features of size.
Drop templates or CMM inspections at a number of points as specified by the Chrysler Dimensional Control Team
shall be required to check all mating surfaces.
A protected copy of the GD&T sheet (in a plastic sleeve, three ring binder, etc.) pertaining to the subject part shall
be attached to the fixture.
B2.1.4 Certification
Surface of the fixture shall be three millimeters (3.00 mm) less than the full part feature surface.
Net pads shall only be incorporated at all surface GD&T datum callouts per part model.
All fixtures shall under go a repeatability (GR) study prior to part shipment to Chrysler. In-process fixtures are the
responsibility of the supplier. Chrysler shall provide funding for detail/assembly fixture only.
Fixture shall be certified prior to initial part submission and after engineering revisions.
B2.1.5 Fixture Certification Tolerances
All product math data is assumed basic (nominal), unless otherwise noted.
Hold fixture flush checks to +/- 0.20 mm from nominal and within +/- 0.10 mm over length of surface being
checked.
All net surface and locating pin positional tolerances to math model shall be +/- 0.10 mm.
Hold 3.0 mm feeler checks to +/- 0.12 mm from nominal and within +/- 0.10 mm over length of surface being
checked.
Datum locating pin diameter tolerance: + 0.00 /- 0.02 mm.
Datum net blocks in the non-critical axis to the math model within +/- 1.0 mm unless otherwise approved by the
Chrysler Dimensional Control Team.
Pin check location tolerance: +/- 0.10 mm.
Sight check tolerance: +/- 0.20 mm.
3.0 mm clear area tolerance: +/- 0.50 mm.
B2.1.6 Datum Pad Certification
Five (5) points per PLP pad shall be certified by CMM data. The five (5) check points are specified per the G, D &
T sheet and are included in the CATIA math model.
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C.2.1 Base
Fixture base should be made of welded tubular construction or 1/2 aluminum tooling plate.
C.2.2 Gage Materials
Non-contact gage fixtures shall be constructed from
NAAMS components.
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D.0.0 S0 General
This appendix standard provides a common S0 gage standard used by all Chrysler Engineering Departments
except Power Train Engineering.
References in this Appendix D to other chapters of GEDOC001 that contain text of ... Chrysler Gage Process
Engineers are to be replaced with Chrysler Dimensional Control Team for items pertaining to Appendix
D.
D.0.1 S0 Gage Requirements
This standard gives the S0 gage source guidance in the requirements for design, build, inspection and
certification of Chrysler S0 gages to check all body-in-white, trim and chassis components. These Chrysler Gage
Standards shall be adhered to for all S0 gage fixtures.
D.0.2 QS-9000 Requirement
Chrysler supports the Tooling and Equipment (TE) Supplement to QS-9000. This Supplement with the QS-9000
manual, along with the Quality System Assessment, Tooling & Equipment (QSA-TE) and the Reliability &
Maintainability Guideline (from SAE & NCMS) will provide the necessary building blocks to construct a quality
system that will continually improve the quality, reliability, maintainability and durability of the S0 gages supplied
to Chrysler. S0 Gage suppliers to Chrysler shall comply with the requirements in the TE Supplement to QS-9000.
D.0.3 Deviation to Standard
Deviations from these standards may be granted from the Chrysler Dimensional Control Team in writing and
would be included with the standard as part of a specification package.
D.0.3.1 Quotation Requirement
All quotations shall then state that the S0 gage fixture being quoted will be designed and built to the specification
package and/or Chrysler S0 Gage Standard.
D.0.4 Approval Qualifications
S0 Design approval shall not constitute a waiver or guarantee of responsibility for any S0 gage purchased by
Chrysler Corporation. An approved S0 gage design does not constitute a certified or functional S0 gage.
D.0.5 S0 Gage Environment
S0 gages must be used in a clean environment and cannot be used as qualifying tools or weld fixtures during the
S0 build.
D.0.6 Build Sources
Chrysler approved/recommended design/build sources shall be used unless prior approval is given by the
Chrysler Dimensional Control Team.
(Reference GEDOC001 Chapter 12.)
1-6
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PART SECTION
A
3.0 FEELER
CHECKING FIXTURE
Figure D.2.A
D.2.3 Feeler Check
S0 Fixtures shall allow access for feeler gages in areas identified as feeler check surfaces. The feeler check
surface should be CNC cut exactly 3.0mm from the product surface. This surface should extend around the
entire periphery of the part. If the profile tolerance is equal to or larger that +/- 3.0 mm, the surface should be
CNC cut to 6.0 mm from the product surface. (See figure D.2.A.)
D.2.4 CMM Access
S0 Fixtures shall allow access for CMM measurement at locations identified as CMM measurement points.
D.2.5 Datum Pad
All datum pads shall be constructed from 3.0 mm brass or cold rolled steel. Chrysler supplied GD&T sheets will
determine the location of the datums. These net pads are screwed to the fixture plank.
D.2.5.1 Datum Pad Clamp
Every datum pad will have a clamp, unless otherwise specified. Clamps will NOT be attached to REN plank. All
clamps must fasten to the aluminum base.
D.2.5.2 Datum Size
Unless otherwise specified, a datum size of 25.00 mm square will be considered standard.
D.2.5.3 Net Pads
All net pads shall be net to the surface of the part except at internal and external angles of net pads. Clearance to
the described angles shall be incorporated.
D.2.6 Gage Pins
Locating pins shall be in accordance with the part model GD&T sheet.
3-6
PART SECTION
3.0 FEELER
CHECKING FIXTURE
4-6
Figure D.2.B
D.2.8 Sight Check
A machined sight check is required for all non-critical holes, slots, and cutouts. A scribe pin and bushing may also
be acceptable to check critical holes with approval of the Chrysler Dimensional Control Team. For the scribe pin
and bushing configurations, refer to GEDOC001 Figure 6.4b.
D.2.9 Drop Template
Drop templates or CMM inspections at a number of points as specified by the Chrysler Dimensional Control Team
shall be required to check all mating surfaces.
D.2.10 Operation Description Sheets (ODS)
Operation Description Sheets describe the initial set-up of checking fixture, the loading of the part, the sequence
of clamping operation and clear instructions for all feature inspections.
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Refer to the
7. Gage Buy-Off Form (GEFM009 xx, supplied by CHRYSLER Dimensional Control Team).
D.4.3 Fixture Data
A plastic envelope shall be permanently attached to the S0 gage fixture. The envelope will contain the graphic
sketch showing the diamond part and its characteristics, the ODS (covered in plastic), the part model GD&T
sheet(s), if applicable, and the certification report. This documentation shall be part of the S0 Gage record at all
times.
D.4.4 S0 Gage Delivery
S0 Gage suppliers are responsible to deliver the S0 gage to the location of the final users with the same condition
as recorded at the time of S0 Gage fixture Buy-off.
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APPENDIX E. Meisterbock
E.1.0 Definition
A holding fixture, designed with multiple GD&T strategies, used for holding several parts and/or assemblies. This
fixture has known X, Y, and Z tooling spheres for the purpose of setting up measuring alignments. It also is
equipped with adjustable locators and spacers, for the purpose of moving parts and assemblies away from design
position, for root cause analysis.
E2.0 Meisterbock Team
The Chrysler Meisterbock Team consists of:
1. Product Releasing Engineer (Product Team Leader or his designate.)
2. Suppliers Gage Engineer.
3. Program Dimensional Lead (Or his designate.)
4. Metrology Systems Lead (Or his designate.)
5. Chrysler Gage Engineer
E2.1 Meisterbock Team Tasks
1.
The Metrology Systems Lead picks a Design and Construct supplier from the recommended list (Gage
Standards Chapter 12) to design and construct the fixture.
2. Suppliers Gage Engineer develops a Timing Chart for the design and construction of the Meisterbock,
along with developing and managing an open issues list. The timing chart will be stored in ProjectWise.
3. The Program Dimensional Lead, with the Product Team Leader, will develop and maintain a CAD file
directory. This directory will contain the currently released CAD product files for the design and
construction of the Meisterbock.
This data will be transferred to the Supplier after CAD- Step 3 and individual files will be re- sent if any
CAD product files are updated.
4. The Chrysler Gage Engineer will schedule the required design review and buyoff meetings.
E3.0 Buyoff Requirements
1. A list of part numbers and Engineering Change (E/C) levels for each part. (This list will match the currently
provided list referenced in APPENDIX E.2.2; Step 3 of this appendix.) This list will be stored in
ProjectWise
2. At the Buyoff meeting, the Supplier will be required to provide:
i) Signed Fixture Design review forms
ii) Inspection data and graphical roadmap.
iii) Fixture GD&T sheets.
iv) Operation Description Sheets or equivalent.
v) Print of Fixture design and stock list.
vi) Fixture 3D CAD models
3. GR / GR&R are not required for a Meisterbock
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4. After the buyoff form has been issued, the Supplier, in conjunction with the Chrysler Gage Engineer, will
manufacture and affix the following Meisterbock identification tag to the fixture. This will be done prior to
shipment.
5. Any changes to the fixture, driven by product or GD&T updates, will be recorded in ProjectWise. These
changes will be recorded in a log sheet and will include the following information:
i) Part Number changed.
ii) Current part revision level for part driving the change.
iii) Brief description of change to identified detail.
iv) Name of Chrysler Gage Engineer authorizing change.
v) Date the change was incorporated into the fixture.
(Note: A copy of the current log sheet will be kept with the fixture.)
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