Dynamic Control Plan Update

Customer: Part #: Part Name :
Rev:
Supplier Code :
Manufacturing Processes Used
Change to Process
and description of change )
(list
DCS-1001
REV:1/6/11
nge )
(list process #
DCS-1001
REV:1/6/11
DYNAMIC CONTROL PLAN

Process Flow Diagram (PFD) Legend
Step (Process )
2 3 4 5 6
Burgaflex North America

Prototype Pre-launch Dynamic Control Plan Number: Part Number/ Latest Change Level: BNA Processes Part Name/ Description : BNA Processes Production X BNA1 Manufacturing orders represent part of this Dynamic Control Plan Fit / Function Safety Critical Supplier / Plant: Burgaflex North America Core Team: Manufacturing Personel P1 P2.. Plant 1 Plant 2 Key Date: Supplier/ Plant Approval/ Date : Supplier Code: BNA Key Contact/ Phone : Date (Orig.) : 1/6/2010
Operation Inspection Move Store
Customer Eng Approval/ Date
Phil Handa , Pat Metzger ,
Tim Hendricks
Other Approval/ Date (If Req'd)
Customer Quality Approval/ D
PFD
Process Flow Occurrence Potential Failure Mode Potential Effect(s) Of Failure Severity Class Process Function Requirements ( 29B
Tube Cut
PFMEA
Potential Cause(s) / Mechanism(s) Of Failure Current Process Controls Prevention Current Process Controls Detection Detection R P N Recommended Action(s) Responsibility & Target Completion Actions Taken Date Action Results OCC RPN DET SEV Machine Device Jig, Tools for MFG. Characteristics Product Process
CONTROL PLAN
Methods
Product/ Process / Specification/ Tolerance Evaluation/ Measurement Technique
Material Transfer )
Long Short Out of round Chatter Part not assemble Part not assemble Endform process Rough Surface 3 3 3 3 Stop set to long Stop set to short /Shavings on stop Clamp to tight 3 3 3 2 Saw procedure Saw procedure Use drops to test Saw procedure 1rst pc inspection / 2nd verification 1rst pc inspection / 2nd verification 1rst pc inspection / 2nd verification 1rst pc inspection / 2nd verification 5 5 5 5 45 45 45 30 Cold Saw Tube Cut No chatter Visual Cold Saw Cold Saw Tube Tube Cut Cut .060 +/.060 +/Tape Measure Tape Measure
Dynamic Control Plan
P1
Saw speed not set properly
Reduce and bead P1 / P2
Large Diameter Smalll Diameter short
Bead to large bead to small will assmble properly
7 7 7
Loose , Not set Properly Loose , Not set Properly Material build up from parts
2 2 2
Endform Procedure Endform Procedure Blow out tooling
1rst pc inspection / SPC collection 1rst pc inspection SPC collection 1rst pc inspection / SPC collection
5 5 5
70 70 70
Manchester Manchester Manchester
tube tube tube
endform endform endform
BNA Spec
Calipers Calipers Calipers
Bead and shell P1 / P2
Large Diameter Smalll Diameter shell not attached
Bead to large bead to small No shell
7 7 7
flag Loose , Not set Properly flag Loose , Not set Properly no shell in clip
2 2 2
Endform Procedure Endform Procedure Endform Procedure
1rst pc inspection / SPC collection 1rst pc inspection SPC collection 1rst pc inspection SPC collection
5 5 5
0 0 0
Manchester Manchester
tube tube
endform endform
BNA Spec
Calipers Calipers
Roll groove
Shallow to deep
Potential part failure Potential part failure
7 7
setup to light setup to deep
2 2
Endform procedure Endform procedure
1rst pc inspection / SPC collection 1rst pc inspection / SPC collection
5 5
0 0
tube tube
endform endform
BNA Spec
Calipers Calipers
P1
Printed copy forreference only - uncontrolled copy

Step (Process )
7A 7B 7C 7D 8 9 10

Tim Hendricks
PFD
Process Flow Occurrence Potential Failure Mode Potential Effect(s) Of Failure Severity Class Process Function Requirements Potential Cause(s) / Mechanism(s) Of Failure Current Process Controls Prevention
PFMEA
Current Process Controls Detection Detection R P N Recommended Action(s) Responsibility & Target Completion Actions Taken Date Action Results OCC RPN DET SEV Machine Device Jig, Tools for MFG. Characteristics Product Process
CONTROL PLAN
Methods
Assemble and Endform
Incorrect fitting
Will not assemble
wrong fitting pulled
Manufacturing order
1rst pc inspection
Manchester
tube
Assemble
Visual
Backwards fitting
Will not assemble
Assembled Backwards
Visual
1rst pc Inspection
Hose Bead
Large Diameter Smalll Diameter
Hose not assemble Hose to loose
6 6
Flag Loose , Not set Properly Flag Loose , Not set Properly
2 2
Endform Procedure Endform Procedure
1rst pc inspection / SPC collection 1rst pc inspection SPC collection 1rst pc inspection / SPC collection 1rst pc inspection SPC collection 1rst pc inspection / SPC collection 1rst pc inspection / SPC collection 1rst pc inspection SPC collection
5 5
0 0
tube tube
endform endform
SAEj1231
Calipers Calipers
P1 / P2 Long / Short Pilot P1 / P2

Large Diameter Smalll Diameter short Flag Setting Flag Setting Buildup in punch 6 7 7 Loose , Not set Properly Loose , Not set Properly Material build up from parts 2 2 2 Endform Procedure Endform Procedure Blow out tooling 5 5 5 0 0 0 Manchester Manchester Manchester tube tube tube endform endform endform DTW1046 IMACA Calipers Calipers Calipers
Double Flare
Large Diameter Smalll Diameter
Flag Setting Flag Setting
7 7
Loose , Not set Properly Loose , Not set Properly
2 2
Endform Procedure Endform Procedure
5 5
0 0
tube tube
endform endform
Calipers Calipers
ID Stamp
Mis identified
Unable to identify
setup incorrect
ID stamp procedure
1rst pc inspection
ID Stamp
Tube
Identification
ID Samp 1001
Hole wrong location
will not function properly
setup / stopincorrect
Drill procedure
1rst pc inspection
Drill
Tube
Hole drill
Height gage
Drill P1
Assembly P2
Backwards fittig crooked fitting
will not assemble Will not function properly
3 3
Loaded incorrectly misaligned
3 3
Assembly Procedure Assembly Procedure
1rst pc inspection 1rst pc inspection
5 5
0 0
Assembly Assembly
Tube & fittings Tube & fittings
Assembly Assembly
Visual Visual

Step (Process )
11 12A 12B 12C 13B 14A 14B 14C 15

Tim Hendricks
PFD
PFMEA
CONTROL PLAN
Methods
Product not clean Residual soap onproduct
Contamination Contamination
3 3
Potential failure in braze process Potential failure in braze process
3 3
Cleaning process Cleaning Process
5 5
0 0
Wash Tub Rinse Tub
Components Components
Cleaning Rinse
Visual Visual
P3 Cleaning
Silver Braze-Torch
Not enough silver
Possible leak
not enough applied
Silver Braze procedure /visual check Silver Braze procedure /visual check Silver Braze procedure /visual check Silver Braze procedure /visual check Silver Braze procedure /visual check Silver Braze procedure /visual check
1rst pc inspection
Silver Braze
Tube & fittings
Torch Braze
Visual
To much silver To Hot
Visual Issues To much carbon
3 3
Possible assembly issues Plating issue
2 2
6 6
0 0
Silver Braze Silver Braze
Tube & fittings Tube & fittings
Torch Braze Torch Braze
Visual Visual
Silver Brazeinduction
No ring Pull part before cooling
No fillet in joint Crooked fitting / possible gaps in joint Possible gap in joint
3 3 3
Ring not inserted Possible assembly issue / leak not enough applied
2 2 2
1rst pc inspection 1rst pc inspection 1rst pc inspection
6 6 6
0 0 0
Silver Braze Silver Braze Silver Braze
Tube & fittings Tube & fittings Tube & fittings
Induction Braze Induction Braze Induction Braze
Visual Visual Visual
P2
To Little Flux
No Braze Incomplete fillet
No fillet in joint Gap in fillet Bad part
5 5 7
No Ring Insufficent paste Missed component
2 2 2
P3 Braze procedure Machine settings Part procedures
100% Test air under water 100% Test air under water Visual instructions
6 6 4
0 0 0
Aluminum Braze Aluminum Braze Aluminum Braze
Tube & fittings Tube & fittings Tube & fittings
P3 Bazeer P3 Bazeer P3 Bazeer
P3 Braze
Missing component
Silver Braze Outside process
Potential leak
Failure in field
Gap in Joint
100% visual joint check
Silver Braze
Tube & fitting
Torch Braze
Visual
( 29B Material Transfer)

CNC Bend P1 / P2 Long Short Bent wrong stop set long stop set short Program incorret 7 7 7 Not set Properly / loose 3 3 3 CMM / Gage / Layout CMM / Gage / Layout CMM / Gage / Layout 1rst pc inspection 1rst pc inspection 1rst pc inspection 3 3 3 0 0 0 CNC Bend CNC Bend CNC Bend Tube Tube Tube Bend Complete Bend Complete Bend Complete CMM / Layout / Gage
Not set Properly / loose Incorrect values
Pines Bend P1 / P2
Long Short Bent wrong
stop set long stop set short Stops not corrtec
7 7 7
Not set Properly
3 3 3
CMM / Gage / Layout CMM / Gage / Layout CMM / Gage / Layout
1rst pc inspection 1rst pc inspection 1rst pc inspection
3 3 3
63 63 63
Manual
Tube
Bend Complete CMM / Layout / Gage
Not set Properly Loose stops
Long Short Trim Operation P2 Cut on angle
Part not assemble Part not assemble
3 3
Stop set to long Stop set to short
3 3
Saw procedure Saw procedure
1rst pc inspection / 2nd verification 1rst pc inspection / 2nd verification
5 5
45 45
Trim Saw Trim Saw
Tube Tube
Cut Cut
Tape Measure Tape Measure

Step (Process )
16 17 18 19 20 21 22 23

Tim Hendricks
PFD
PFMEA
CONTROL PLAN
Methods
Weld P2
Bracket wrong location will not assemble
Bracket not set properly
Weld Tooling / CMM
1rst pc inspection
84
Welder
Bracket to tube
Weld complete
CMM / Layout / weld tool
( 29B Material Transfer)

Testing Part leak Missed operation 7
Operation bypassed
GP logging does not allow Manufacturing order processes to be bypassed
36
Testing
assembly
Air underwater
BNA Test pressures 250 PSI 90 sec
Pressure gage
P1 / P2
Testing
assembly
Air underwater
110 PSi 420 PSI
Pressure gage
Plating / Paint
Flaking Discolored Rust
unhappy customer unhapy customer unhapy customer
6 6 6
poor plating poor plating Contamination
3 3 3
Receiving Inspection Receiving Inspection Receiving Inspection
Receiving Inspection Receiving Inspection Receiving Inspection
3 3 3
0 0 0
Plating Plating ID tube
Coating Coating Part
Plaiting / paint Plaiting / paint Plaiting / paint
Proper coat Clean Hue No rust
Outside Process
( 29B Material Transfer) Coring Mising Core Not tightened enough

Leakage Leakage 5 5 Not asembled Tourque insufficient 2 2 Pre set tourque tools Visual verification durring packaging Pre set tourque tools 2 2 0 0 manual assembly Valve core tool Valve core Valve core Assemble Valve core Torque valve core Visual Pre set torque tools
Roll Flare P1
Not formed enough Formed to much Damage to sealing surface
Possible improper seal Possible improper seal Possible leak
6 6 6
Not pulled Enough Pulled to much Tooling damaged
2 2 2
Operator training Operator Training Tooling check during setup
100% to snap gage 100% to snap gage !00% visual
6 6 6
72 72 72
Roll Flare Roll Flare Roll Flare
Single Flare Single Flare Single Flare
Flare Flare Flare
Snap Gage Snap Gage Visual
Cut Hose P1
To long To Short
Possible product to Long Possible product to short Possible product to Long Possible product to short
6 6
Stop set to Long Stop set to short
2 2
Adjustable stop Adjustable stop
5 5
60 60
Hose Cutter Hose Cutter
Cut Cut
Hose Hose
Per MO Per MO
Tape measure Tape measure
Cut Loom P1
To long To Short
6 6
Stop set to Long Stop set to short
2 2
Adjustable Stp Adjustable stop
5 5
60 60
Loom Cut Loom Cut
cut cut
Loom Loom
Per MO Per MO
Tape measure Tape measure
Pull Sub Assemblies
Wrong assembly
Parts incorrect
Mis identified
Final Inspection
1rst pc inspection
30
Pull Assem
Sub Components
Pull Sub Components
Per MO
visual

Step (Process )
24 25 26 27 28

Tim Hendricks
PFD
Process Flow Occurrence Potential Failure Mode Potential Effect(s) Of Failure
will not assemble will not assemble Possible failure Possible Failure
PFMEA
Potential Cause(s) / Mechanism(s) Of Failure
Rotation tooling not used ends crimmped to wrong end setup incorrect setup incorrect
CONTROL PLAN
Detection R P N
90 90 60 60
Severity
Class
Process Function Requirements

Assemble and crimp P1
OCC
RPN
DET
SEV
Current Process Controls Prevention
Current Process Controls Detection

1rst pc inspection Inprocess inspection Inprocess inspection Inprocess inspection
Recommended Action(s)
Responsibility & Target Completion Actions Taken Date
Action Results
Machine Device Jig, Tools for MFG.

Assem Crimp Assem Crimp Assem Crimp Assem Crimp
Characteristics Product
Crimp Crimp Crimp Crimp
Methods
Process
Crimp Complete Crimp Complete Crimp Complete Crimp Complete
Wrong Rotation Crimmped incorrectly Crimp to tight Crimp to lite
6 6 6 6
3 3 2 2
Rotation Tooling 1rst pc inspection 1rst pc inspection 1rst pc inspection
5 5 5 5
Customer Print / Per MO Customer Print / Per MO Customer Print / Per MO Customer Print / Per MO
Rotation Tooling Rotation Tooling Rotation Tooling Rotation Tooling

Testing P1 / P2
Part leak
Missed operation
Operation bypassed
GP logging does not allow Manufacturing order processes to be bypassed
36
Testing
assembly
Air underwater
BNA Test pressures 250 PSI 110 PSi 420 PSI
Pressure gage
Bundle assembly
Missing Bracket Missing Bolt
will not assemble Bracket loose / fall off Bracket loose / fall off Bundle / Bracket loose
3 3 3 3
Missed during assembly Missed during assembly Missed during assembly Missed during assembly
2 2 2 2
Assembly tool Assembly tool Assembly tool Assembly tool
1rst pc inspection 1rst pc inspection 1rst pc inspection 1rst pc inspection
6 5 5 5
36 60 60 60
Bundle Assem Bundle Assem Bundle Assem Bundle Assem
Assem Assem Assem Assem
Assembly Assembly Assembly Assembly
Assembly tool Assembly tool Assembly tool Assembly tool
P1
Missing Nut Missing sleeve
Assemble and pack
Missing cap Mislabled
Contamination Unable to identify
3 3
Missed during assembly Labels made incorrectly
3 3
Visual Visual
4 6
36 54
Pack Pack
Full Assembly Full Assembly
Assembly Assembly
Final Inspection Final Inspection
P1
Cleanliness Test P1
Test not completed
Possible contaminated materil
Operation Bypassed
GP logging does not allow Process listed on processes to be bypassed manufacturing order
24
Gravimetric test
Ful assembly
Cleanliness Test
Cleanliness Test

Step (Process )
29 30A 30B

Tim Hendricks
PFD
PFMEA
CONTROL PLAN
Methods
GP-12 / CS-1 P1 / P2
GP-12/CS-1 not completed
Possible Failure during safe launch
Process bypassed
Assembly Tooling
100% Verification
60
Assembly Tools
Full Assembly
GP-12
Assembly Tools, Layout
Shipped to Wrong Location
Dissatisfied customer
Mislabled
Label to part verification
84
Label Maker
Finished Product
Shipping
Visual label to product check
Shipping P1 / P2
Mislabled
Missing Product
Not correctly labeled
Label to Shipper verification
Label to Shipper verification
16
Label Maker
Raw Material
Shipping
Visual label to product check
Revision
1
Revision Date
6/14/2011 11/15/2010 1/12/2012
Description Added 110 psi to process

Added recomended actions to RPN higher than 100 Added Material transfer Added Coring process Added P3 braze and cleaning , updated RPN with changes made Added Trim Process
2 3
4 5 6
1/16/2012 1/18/2012 2/11/2012

Date (Rev.) : 2/11/2012
er Eng Approval/ Date (If Req'd)
er Quality Approval/ Date (If Req'd)
L PLAN
Methods Sample Freq. Size Control Method Reaction Plan
Contact supervisor sort 100%
50
Saw Procedure / manufacturing order Saw Procedure / manufacturing order
Saw Procedure / manufacturing order
4 samplings per day per setup
Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order
Contact supervisor sort 100% Contact supervisor sort 100%
Endform Procedure / Manufacturing order 4 samplings per day per setup Endform Procedure / Manufacturing order

Date (Rev.) : 2/11/2012
L PLAN
Endform Procedure / Manufacturing order
100% Each Lot
Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order
4 samplings per day per setup Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order 4 samplings per day per setup Endform Procedure / Manufacturing order Endform Procedure / Manufacturing order Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
50
I stamp procedudre
50
Drill Procedure
100% 100%
each lot each lot
Manufacturing order / Assembly procedure Manufacturing order / Assembly procedure
10

Date (Rev.) : 2/11/2012
L PLAN
100% 100%
each lot each lot
Manufacturing order / Cleaning procedure Manufacturing order / Cleaning procedure
100%
each lot
Manufacturing order / Silver braze procedure Manufacturing order / Silver braze procedure Manufacturing order / Silver braze procedure Manufacturing order / Silver braze procedure Manufacturing order / Silver braze procedure Manufacturing order / Silver braze procedure
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
Manufacturing order /P3 Contact supervisor Braze Procedure sort 100% 100% Test air under water Manufacturing order /P3 Contact supervisor Braze Procedure sort 100% 100% Each Lot Manufacturing order /P3 Contact supervisor Braze Procedure sort 100%
100%
Each Lot
Sort 100% contact supplier
50
Bend Procedure
50
Bend Procedure Contact supervisor sort 100%
11

Date (Rev.) : 2/11/2012
L PLAN
100%
Each Lot
Weld Procedure
Test complete and scrap / repair 100% Each Lot Manufacturing order / Test procedure / validation Testing
Test complete and scrap / repair
5 each lot 5 each lot 5 each lot Receiving inspection procedure
Return to supplier Return to supplier Return to supplier
100% each Lot
Coring procedur
Manufacturing order / Flare procedure 100% Each Lot SAEJ1231
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
50
Manufacturing order Manufacturing order
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
50
Manufacturing Order Manufacturing Order
Lot
Tag
Manufacturing Order
12

Date (Rev.) : 2/11/2012
L PLAN
Methods Sample Freq.
1
Size
Control Method
Manufacturing Order Manufacturing Order Manufacturing Order Manufacturing Order
Reaction Plan
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
50
100% Each Lot
Manufacturing order / Test procedure / validation Testing SAEJ2069
Test complete and scrap / repair
Manufacturing order Manufacturing order 100% Each Lot Manufacturing order Manufacturing order
Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100% Contact supervisor sort 100%
Manufacturing Order Manufacturing Order
Per lot
Manufacturing order
13

Date (Rev.) : 2/11/2012
L PLAN
Manufacturing Order 100%
Each Lot
100% Each Lot
Shippers
Shippers
14

Dynamic Control Plan Update

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Dynamic Control Plan Update

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Customer: Part #: Part Name :

Manufacturing Processes Used

and description of change )

DYNAMIC CONTROL PLAN

Burgaflex North America

Operation Inspection Move Store

Customer Eng Approval/ Date

Phil Handa , Pat Metzger ,

Other Approval/ Date (If Req'd)

Customer Quality Approval/ D

Dynamic Control Plan

Saw speed not set properly

Reduce and bead P1 / P2

Large Diameter Smalll Diameter short

Bead to large bead to small will assmble properly

Endform Procedure Endform Procedure Blow out tooling

Manchester Manchester Manchester

tube tube tube

endform endform endform

Calipers Calipers Calipers

Bead and shell P1 / P2

Large Diameter Smalll Diameter shell not attached

Bead to large bead to small No shell

Endform Procedure Endform Procedure Endform Procedure

Potential part failure Potential part failure

setup to light setup to deep

Endform procedure Endform procedure

1rst pc inspection / SPC collection 1rst pc inspection / SPC collection

Printed copy forreference only - uncontrolled copy

DYNAMIC CONTROL PLAN

Burgaflex North America

Operation Inspection Move Store

Customer Eng Approval/ Date

Phil Handa , Pat Metzger ,

Other Approval/ Date (If Req'd)

Customer Quality Approval/ D

Assemble and Endform

Will not assemble

wrong fitting pulled

Dynamic Control Plan

Will not assemble

Large Diameter Smalll Diameter

Hose not assemble Hose to loose

Endform Procedure Endform Procedure

P1 / P2 Long / Short Pilot P1 / P2

Large Diameter Smalll Diameter

Flag Setting Flag Setting

Loose , Not set Properly Loose , Not set Properly

Endform Procedure Endform Procedure

Hole wrong location

will not function properly

Backwards fittig crooked fitting

will not assemble Will not function properly

Loaded incorrectly misaligned

Assembly Procedure Assembly Procedure

1rst pc inspection 1rst pc inspection

Tube & fittings Tube & fittings

Printed copy forreference only - uncontrolled copy

DYNAMIC CONTROL PLAN

Burgaflex North America

Operation Inspection Move Store

Customer Eng Approval/ Date

Phil Handa , Pat Metzger ,

Other Approval/ Date (If Req'd)