Purpose The purpose of the AME/ASME Gage Standards is to provide Chrysler personnel and suppliers with a reference source for required design and construction standards for gage fixtures.
Audience Any current and potential Chrysler suppliers, Chrysler contractors/employees and the general public.
General Overview
AME/ASME Chrysler Gage Standards may be viewed and/or printed from your browser by section.
This version of AME/ASME Gage Standards revised 8/01/2010.
Software Requirements
A Web Browser, such as Netscape or Internet Explorer. It is recommended to use the corporate standard Internet Explorer for intra-Chrysler access.
Chrysler Contacts
For content questions please contact: Bill Bielby at (248) 576-0775 {Tie Line 776-0775] Email: mailto:[email protected]
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1 2 3 4 5 6 7 8 9 10 11 12 Appendix A B B2 C D E
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CHAPTER 1.0 INTRODUCTION To: All Users From: Bill Bielby, Gage / Process Engineer Phone: 248-576-0775 (Tie Line: 776-0775) Email: [email protected]
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).
- ASME Gage Standards & Process responsible to chair and update Chrysler Design and Build Gage Standards. - Updates canvassed from BIW Gage Process, Stamping Gage Process and the Chrysler users plus run plants. - Gage Standards will review revisions to the standards before submitting for review and approval by BIW Gage Process, Stamping Gage Process and the Chrysler users plus run plants.
1.3 GAGE STANDARD CHANGE PROCEDURE:
Standards are reviewed semi-annually for update.
Gage standards + form change requests are to be submitted in MQAS through the "Document Change Request" (DCR) process form found in the "Released Documents" Lotus Notes database for document GEDOC001xx.
All change requests will be submitted by a Gage Process Engineer for review.
Addresses for viewing most current Chrysler AME/ASME Design and Build Gage Standards:
2.1.1 All gage designs become the property of Chrysler.
2.1.2 Gage designs shall be a Computer Aided Design (CAD). Manual gage designs require approval by Chrysler. Gage designs that are required to be designed in CATIA Solid-E; see the Chrysler Gage Process Engineer for direction and approval.
2.1.3 All CAD gage designs will be formatted in CATIA at time of delivery. (Chrysler user run plants only).
2.1.4 Holding fixtures shall be designed in CATIA Solid-E for Chrysler user plants
2.1.5 All gages shall be designed in metric.
(Note: English units used for where available standard stock sizes or cost considerations are necessary. ALL designs remain shown with metric equivalent.)
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.
C. Free accessibility to all components for ease of maintenance and replacement.
D. Rigidity of construction for operation endurance for the life cycle of the vehicle.
2.1.12 After all issues from the 40% and 90% design reviews are resolved, the gage manufacturer is authorized to begin build. This authorization is documented on the Gage Design Kick-off, Review, and Approval Form (GEFM001xx) and is signed by the lead Chrysler Gage Process Engineer.
2.1.13 Upon shipment of the gage fixture to the Chrysler User Run Plant, the designs are updated and to include gage fixture dimensions and weight. Then, ship designs as directed by Chrysler Gage Process Engineer.
2.2 Design Layout Requirements
2.2.1 The fixture base will be parallel to the X, Y, or Z plane of vehicle. Base orientation will be determined by the Chrysler Gage Process Engineer.
2.2.2 Alignment features shall be shown on the gage drawing, targets and tooling balls.
2.2.3 All gage designs shall be identified with Chrysler Gage Numbers as shown on the MEDDS specification for each design. Utilize the standard stock list (Figure 2.2a).
2.2.4 The base height shall be determined by the average inspection height of 1000.0 mm.
2.2.5 All math models required for the gage design shall be listed in the space provided. List part number, drawing or layout number, name and latest change (Figure 2.2a).
2.2.6 List name, address, and phone number of manufacturer/supplier of all purchased parts on gage drawing. (Reference: stock list).
2.2.7 List Chrysler commodity codes in the Standard Stock List. (Chrysler Design & Build ONLY. See Chrysler Gage Design or Process Engineer.)
2.2.8 All bases larger than 48 inch x 48 inch will have legs and must be steel, unless otherwise noted by Chrysler Gage Process Engineer.
2.3 Design Status
2.3.1 Design status reports are required weekly as directed by the Chrysler Gage Process Engineer.
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.
3.1 General NOTE: Manual gage design requires approval by Chrysler Gage Process Engineer.
3.1.1 Body lines shall be called out and stamped on finish adjacent edges of base, and the units that are mounted to the base.
3.1.2 Use color for all part lines. A different color shall be used for each part. The identification of a part shall be called out at least once on each gage design.
3.1.3 Identify net areas of the gage with cross-hatching.
3.1.4 Identify materials being used in cross sections with cross hatching.
3.1.5 Diamond characteristics identify on appropriate views and section.
3.2 Layout Format
3.2.1 The gage design layout shall conform to and contain the information as contained in Standard Stock List.
3.2.2 Change balloons shall be used with all revisions on layouts, stock list and on borderline.
3.2.3 Use a 10.0 mm diameter balloon for change letters.
3.2.4 The minimum sheet size is "D" size, 24.0 inch x 36.0 inch.
3.2.5 The maximum length of a sheet shall be 12.0 feet, with a maximum width of 42.0 inches.
3.2.6 All sheets shall have a 0.50 in. border all around.
3.2.7 Designs shall be full size, unless otherwise specified.
3.2.8 Major panel designs shall have a key sheet which may be at a reduced scale.
3.2.9 A full plan view of the part and gage base is required on fixtures that are symmetrical about the centerline. The gage design shall show and detail the Right Hand side of fixture and any Left Hand only details.
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).
4.1.1 The design shall adhere to Chrysler supplied product math model, and the MEDDS / AMPS detailing gage concepts.
4.1.2 Detailing is not required for CAD design, unless requested by Chrysler Gage Process Engineer.
4.1.3 CAD model of compatible references are furnished, when available (for reference only).
4.1.4 Designs shall be broken into sub-models. Each sub-model will consist of one complete stack of gage "fixturing" from product surface to base surface. For DEA flexible tooling, each module assembly shall have its own sub-model, using a unitized system.
4.1.5 CAD model shall be 3D & CNC compatible.
4.1.6 Details shall be identified in 3D wire frame model with a 3D number or CATIA attribute. Note a start point indicating orientation of the detail and the appropriate gage symbol indicating net, flush, feeler, etc.
4.1.7 CAD models shall be separable, individual details shall be in separate layers (base, clamps, composite, etc.)
4.1.8 Each CAD model shall be a complete representation of the finished "fixturing" for that sub-model, showing open position of clamps, templates, etc.
4.1.9 Designs may be completed in wire frame or CATIA Solid-E, as specified in process specification package.
4.1.10 When designing in wire frame, tapped holes and dowel holes shall be represented by a circle of the nominal value with color code attributes from hole diameter. The circle color code shall be placed on the face of the detail where screw or dowel would enter. Counter bored holes shall have actual depth shown on the design. (See Figure 4.1)
4.1.11 When designing in CATIA Solid-E, tapped and dowel holes should be represented by nominal tap drill size with circle color code. (See Figure 4.1)
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 sub-model identification, which designate the model as being right hand shown with the left hand symmetrically opposite.
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.
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).
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.
5.1.1 The base / frame shall be sized so that all clamps and targets do not overhang the periphery of the base / frame when in the open position. Also, there shall be sufficient surface provided on the base for mounting interchangeable tooling, inspection equipment and a Chrysler identification plate.
5.1.2 The base / frame height shall be determined by the average inspection height of 1000.0mm
5.1.3 The part shall be a minimum of 100.0 mm above base/ frame, except CMM holding fixtures (refer to Section 6.13).
5.1.4 Machined surfaces of bases / frames shall be rust-proofed.
5.1.5 All tooling plate gage bases / frames shall have jig feet in the four corners.
5.1.6 Floor bases / frames shall have provisions for leveling, utilizing all base pads include details in stock list.
5.1.7 Sub-base construction with multiple units shall utilize machined corners on the sub-base when units are doweled at assembly. Sub-base corners shall be labeled / stamped.
5.1.8 Base / frame's leg, or cart if base /frame size is less than 48 inches x 48 inches, requirements shall be finalized with the user run plant at the 40% design review and noted in the MEDDS specification. If cart is required, all carts must have a bottom metal shelf located above the casters for part storage.
5.1.9 Legs for bases / frames will be itemized in fixture stock list.
5.1.10 Legs or carts are to be shipped to the user run plant only. Do not ship to die / machine tryout sources. If so released and authorized for shipping, replacement liability will be supplier's responsibility.
5.1.11 All legs will have leveling screws. And, if casters are supplied for legs or carts as agreed upon in Gage Plan, two (2) of the four (4) casters must have locking mechanisms.
5.1.12 Holes for attached legs shall be provided; legs shall be shipped unassembled from base and not to cause damage to check fixture components.
5.1.13 The material for cast aluminum bases shall be SAE 315 or equivalent; with Brinell hardness of 74. The average yield strength shall be 26,000 PSI and a tensile strength of 35,000 PSI. Supplier shall furnish their own pattern.
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 S t e e l
Base Size (base must fit within parameters in both directions)
Base Material Base Size (base must fit within parameters in both directions)
Base Material
6.0 in x 6.0 in to 6.0 in x 12.0 in
1.0 in aluminum tooling plate, Blanchard ground flat & parallel to +/- 0.05 mm overall
18.0 in x 12.0 in to 18.0 in x 18.0 in
0.75 in Thick (clean up) B.P. with Jig Feet 1.50 in x 1.50 in x 0.44 in
12.0 in x 8.0 in to 12.0 in x 16.0 in
1.0 in aluminum tooling plate, Blanchard ground flat & parallel to +/- 0.05 mm overall
18.0 in x 24.0 in to 18.0 in x 30.0 in
1.0 in Thick (clean up) B.P. with Jig Feet in x 1.50 x 0.44 in
18.0 in x 12.0 in to 18.0 in x 18.0 in
1.0 aluminum tooling plate, Blanchard ground flat & parallel to +/- 0.05 mm overall with Jig Feet 1.50 in x 1.50 in x 0.44 in
24.0 in x 24.0 in to 24.0 in x 36.0 in
1.0 Thick (clean up) B.P. with 3.0 in Channel all around 24.0 in x 36.0 in 1.50.0 in from edge of plate with (4) 0.75 in. Thick pads on corners
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
1.0 in Thick (clean up) B.P. with 4.0 in Channel iron all around 1.50 in from edge of plate with (Use mean thickness of web on channel iron) (4) 0.75 in thick pads on corners
36.0 in x 42.0 in to 36.0 in x 48.0 in
Same as above except that maximum thickness for web channel iron to be used
1.25 in Thick (clean up) B.P. with 6.0 in channel all around 3.0 in from edge of plate plus sufficient channel braces and (4) 0.75 in thick 7.0 in x 7.0 in pads on corners. Legs and jack screws shall be provided on all four corners plus (1) in center of base
48.0 in x 84.0 in to 48.0 in x 120.0 in
Same as 48.0 in x 48.0 in except use 8.0 in channel iron
48.0 in x 120. 0 in and over
Same as 48.0 x 48.0 in except use 10.0 in channel iron. Provide for (6) legs and jack screws plus (1) in center of base
5.3 Base Machined Tolerances
5.3.1 Overall "square- ness" relationship of machined edges, length, and width shall be +/- 0.08 mm.
5.3.2 Overall parallelism between top and bottom surfaces shall be +/- 0.08 mm.
5.3.3 Bases / frames shall be flat within +/- 0.13 mm 0.13mm per square foot of area with a maximum of +/- 0.10 mm total in any length.
5.3.4 Base surface finish shall not exceed 80.0 micro inches RMS roughness.
5.4 Line Blocks
5.4.1 Bases / frames larger than 24 in. x 24 in. require a removable line block. (See Figure 5.4a).
5.4.2 Chrysler Gage Process Engineer / user run plant determines line block or machine edge preference.
5.4.3 The hole pattern to locate line block around the gage shall have no more than 400.0 mm between locations.
5.4.4 Position line blocks outside of the gage and part.
5.4.5 Dowel holes in base for line blocks shall be reamed in steel bases and bushed in aluminum base construction. (See Figure 5.4a).
5.5.1 Supplier shall provide swivel clevis type METRIC hoist rings at the four (4) fixture corners if heavier than 60 pounds.
5.5.2 Hoist rings must have the load capacity to lift maximum weight of fixture plus 25%. Eye bolt size shall be determined by maximum load of eye bolts at a 60 degree pull angle.
5.5.3 The eye bolt size shall be stamped near the hole on the base.
5.5.4 Use Helicoil screw locks for aluminum bases.
5.6 Standards for FABRICATED Aluminum Bases
5.6.1 General - Aluminum Derived from Cast Aluminum Specifications.
5.6.2 All bases that are 36” square and under will require four (4) base pads and the center support will be machined on the same plane as the pads. Any base that exceeds 36” in one direction and is under the 48 square inches will require six (6) base pads and the center supports are machined on the same plane. (See example Figures 5.6a and 5.6b.)
5.6.3 The overall height of the base cannot exceed 6” and will be no less than 5”.
5.6.4 Material Specifications - Aluminum The following rules apply for the construction of the bases:
(A) The main base plate will be made out of 6061 T651, stress relieved, 1” thick aluminum.
(B) (4 or 6) 2” x 2” x 3 x ¼” wall stock 6061 aluminum tubing at each corner for bases with (4 or 6) base pads. The tubes will require a 1/8” drilled thru gas release hole on one of the outside faces. (See example Figures5.6a and 5.6b.)
The tubes will consist of 2” x 2” x ¼” w/s x 3 ¼”lg for bases 5” thick and 4 ¼” lg. for bases 6” thick. The base pads will consist of ¾” x 4” x 4”. (5/8” finished approx).
(C) The base skirting and under surface structure for the “X” pattern will consist of 5/8” x 3” x length to suit. (See example Figures 5.6a and 5.6b.)
5.6.5 Weld Specifications - Aluminum Refer to example Figures5.6a and 5.6b for locations and type of weld.
(A) Bases will have a stitch weld in the middle of the base to the tooling plate and skirting approximately 6” long on all (4) sides and spaced approximately 4” apart.
(B) The tubes & base pads will be 100% all around the under surface of the base.
(C) The “X” pattern & parameter of the base will consist of a stitch weld approximately 6” long and spaced approximately 4” apart.
5.6.6 Tolerance and Machining Specifications - Aluminum The following rules apply for the certification of bases.
1. Top and bottom surfaces shall be “blanchard” ground.
2. Overall parallelism between top and bottom surfaces shall be +/- 0.08 mm.
3. Overall "square- ness" relationship of machined edges, length, and width shall be +/- 0.08 mm.
4. Bases shall be flat within +/- 0.13 mm 0.13mm per square foot of area with a maximum of +/- 0.10 mm total in any length.
5. Base surface finish reference Section 5.3.4.
6. All fixture base’s steel or aluminum will have all of the pertinent certification reports contained with the gage certification package.
6.1.1 Fixtures will be NC machined to math data per machining symbols. (Figure 6.1a & 6.1b)
6.1.2
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)
6.1.7 Provide on every gage fixture a GR/GR&R Tag (84-206-0021) supplied by Chrysler Gage Process Engineer. (Figure 6.1c). Chrysler Gage Process Engineer provides tag for each Chrysler user run plant stamping and assembly gage.
6.2.1 The datum’s 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)
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.
6.5.1 All check elements shall be normal to part surface, except flush checks. They may be within 10 degrees perpendicular to base.
6.5.2 Flush checks shall have a minimum of 20.0 mm flush surface (Figure 6.5a); 25.0 mm where possible.
6.5.3 Flush pin type checks may be used only upon approval by the Chrysler Gage Process Engineer.
6.5.4 All Stamping Assembly gages for closure panels shall have complete periphery gage bars. All cut line feeler checks shall be 3.0 mm (Figure 6.5a). Fixture material type will be identified in MEDDS specification and at line-up meeting.
6.5.5 Gage bar supports shall be provided on all gage bars with 50.0 mm or more overhang.
6.6.1 All sight checks shall be 3.0 mm clear from part surface with a minimum depth of 3.0 mm. Sight checks shall be made to virtual condition; maximum material condition (MMC) minus "locational" tolerance, or least material condition (LMC) plus "locational" tolerance if a sight check hole becomes less than 1.5 mm diameter. (See Gage Standards Chapter 2 Design Requirements.)
6.6.2 All holes not pin checked will be sight checked. (Ref. Figure 6.1b)
6.7 Hinge/Template Units
6.7.1 Use Chrysler approved standard commercial angle brackets, risers, hinge drops, template drops, etc. Fabricated or refurbished units may be used with Chrysler Gage Process Engineer approval.
6.7.2 All fabricated drop units shall use bushings at pivot points and bushings when lock pins are used. (Figure 6.7a)
6.7.3 All drop units shall have steel thumb screws locks when lock pins are not used.
6.7.4 Provide stops for all gates, slides, clamps, gage bars, targets, drop templates, etc., in retracted position.
6.7.5 Hinge / template drops shall be steel "T- pinned" and bushed in the bracket / swing units when using SPC and datum nets.
6.7.6 All templates are to be normal to check surface.
6.7.7 All templates are to be contour type, NC machined, and not profiled.
6.7.8 All contour template checks shall be specified as 6.35mm stock - SAE 1018.
6.7.9 Hinge/template drops shall have all sharp edges removed.
Figure 6.7a Bushings and retained T-Pins or L-pins.
6.8 Hand Held Gages
6.8.1 Hand gages shall be designed as small and light as possible. Weight for hand gages shall not exceed 25 pounds for one operator and 60 pounds for two operators. The total weight shall be calculated and indicated on the stock list if over 25lbs and weight stamped on hand gage fixture.
6.8.2 Fixtures without a base (G) and hand templates shall have body line blocks, or a reference origin.
6.8.3 All removable details, which are not mounted on swing templates shall be secured to the gage and stamped with the tool number.
6.10.1 All gages shall be constructed of steel, aluminum, or composite material as determined by Chrysler Gage Process Engineer.
6.10.2 Large fabrications shall be made with welded tubing that has a minimum wall thickness of 6.35 mm (unless otherwise specified by Chrysler Gage Process Engineer) and shall be normalized.
6.10.3 Cast details may be used (except for standard angle brackets and bases), with approval from Chrysler Gage Process Engineer.
6.10.4 All "weldments" shall be normalized (aluminum) and stress relieved (steel) prior to machining.
6.10.5 When aluminum gage bars are utilized, they shall be anodized hard coated.
6.10.6 Minimum surface roughness requirement for gage rings / rails will be 70 microns or better, unless otherwise approved by Chrysler Gage Process Engineer.
6.10.7 Description of Minimum urethane fixture board requirements: a. Color = Gray / Grey b. Hardness (Shore D) @ 75 degree F = 70-75 c. Flexural Modulus, psi = 200,000 d. Thermal Expansion coefficient = -22 to 86 degree F, in/in/degree F= 30 x 10-6
-30 to 30 degree C, mm/mm/degree C = 54 x 10-6
Supply applied urethane fixture board material specifications at time of fixture Design review for Chrysler Gage Process Engineer records. No exceptions, unless otherwise documented & approved by Chrysler Gage Process Engineer.
6.11 Gage colors:
6.11.1 Paint all gage bases light blue, NPVP 2.5 PB 7/6; Chrysler commodity code #65-153-4770.
6.11.2 Paint all non-check elements above base light blue, NPVP 2.5 PB 7/6; Chrysler commodity code #65-153-4770.
6.11.2a Stanchions used on / with CUBE MEASUREMENT SYSTEM shall be:
• 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.
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 #65-153-4770.
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.
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.
6.15.1 Targets (points on edge of base) shall be used for fixture alignment. Two (2) are required on long edge of fixture base and one (1) on short edge and (3) points on base surface. Identify target locations with a scribed circle and provide a tag to cover target location for protection.
6.15.2 (This section eliminated by Chrysler Gage committee, 10/2002.)
6.15.3 Fixtures using Tooling Balls or 12mm I.D. Head Press Fit Metric Bushings require three (3) for alignment. The X, Y, Z coordinates shall be stamped on a tag and mounted on fixture base next to the tooling ball. (Figure 6.15b)
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)
Figure 6.15a CMM Fixture Alignment.
(NOTE: Tooling Balls or Head Press Fit Metric Bushing may be used for alignment.)
7.1.1 The Gage Supplier shall verify CMM inspection data to the latest product CATIA model. A second party (not the author of the CMM check program) shall perform the verification. This can be done internally by the Gage Manufacturer or by an outside third party source. The third party source (See Section 12.C of Gage Standards) selection shall be determined and/or approved by Chrysler Gage Process.
7.1.2 The Gage Supplier will have a documented procedure showing how the verification process is to be accomplished.
7.1.3 Verification of the CMM inspection program requires a minimum of one (1) point checked on each block compared to CATIA data. Flush and feeler rails will be checked with two (2) points on each end (total of eight points) compared to CATIA data
7.2 Inspection
7.2.1 Gage Supplier shall adhere to the requirements for certification and calibration as stated in Element 4.10, Inspection and Testing and Element 4.11, Control of Inspection, Measuring, and Test Equipment in the QS-9000 manual.
7.2.2 Point Spacing:
A. Maximum distance between inspection point is not to exceed 100.0mm.
B. Minimum distance from a tangent is 3mm.
C. For curved surfaces, reduce point spacing to 15-25mm.
D. For radius up to 20mm, generate three (3) points - both ends of tangent and at center for the radius.
E. For radius 20 to 40mm, generate five (5) points - both ends of tangent and three (3) equally spaced on the radius.
F. For radius 40mm and larger, generate ten (10) points - both ends of tangent and eight (8) equally spaced along the radius.
7.2.3 Generating Inspection Points
A. Net Blocks - generate five (5) points; one (1) at each corner and center.
B. Flush & Feeler Check Rails - make rows of points at 5mm and 13mm from hard corner edge.
C. (Eliminated, 10/2002, by Chrysler Gage committee.)
D. Template (contour edge) - make two (2) rows of data; 1mm from each side of blade.
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.
1. All reports will be divided into SECTIONS by FEATURES. 2. All inspections will have a header identifying the Sub-Model & type of inspection. 3. Each page of the report to carry header consisting of Fixture TOOL Number, DATE & PAGE number of
total pages. 4. All HOLE inspections will report SIZE & LOCATE.
EXAMPLE for 7.2.3.H.: (Items in BOLD are added elements for 2004+ Gage inspection reports.)
Tool #S4RLX-5055022 Page 1 - 3 1-05-2004
SUB-05 C/L of 5.25 SIGHT CHECK
DIM D79 = LOCATION OF CIRCLE CIR7 UNITS=MM
AX NOMINAL MEAS + TOL - TOL DEV OUTTOL
X 1993.330 1993.514 0.200 0.200 0.184 0.000
Y 902.520 902.494 0.200 0.200 -0.026 0.000
Z 1140.530 1140.670 0.200 0.200 0.140 0.000
D 5.250 5.274 0.200 0.200 0.024 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.
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.)
8.1.1 All gages shall pass an approved GR&R procedure as outlined in the Chrysler Quality Assurance Work Instruction, GEOP011. The GR&R study shall be performed by the gage supplier and approved by Chrysler Gage Process Engineer prior to shipment to the user run plant. The Chrysler Gage Process Engineer is responsible for the GR&R study for Chrysler ASME / AME gages.
8.1.2 A passed Gage GR/GR&R study tag shall be supplied by Chrysler Gage Process Engineer. This tag will be stamped with the engineering change level, GR&R completion date and the Chrysler Gage Process Engineer stamp to indicate the fixture passed the GR&R study.
8.1.3 The Chrysler Gage Process Engineer shall provide parts to the gage build supplier to conduct GR / GR&R study. The gage construction supplier shall notify the Chrysler Gage Process Engineer prior to conducting study.
8.1.4 If detail parts/assemblies are not available for a GR&R study, a GR study shall be performed. A GR study is an expedient method of demonstrating a measure of gage repeatability.
8.2 GR Study
a.) Fixture must be inspected and certified prior to performing GR study.
b.) To perform a GR study, one part/assembly and one operator is required.
c.) A complete GR study requires that the same part/assembly is loaded, measured and unloaded ten (10) sequential times. This part / assembly must be loaded by the same operator ten (10) sequential times.
d.) Pre-determined points will be measured each of the ten (10) times the part / assembly is loaded. Method of data collection may be done either by CMM machine or hand held electronic data collector. A minimum of two (2) “Up / Down” locations; two (2) “Fore / Aft” locations; and two (2) “Cross-Car” point locations required. (Laser or vision system measurement devices may be used, only if approved by the Chrysler Gage Process Engineer. )
e.) For each of the ten (10) times a part / assembly is to be measured, follow steps (f) through (k).
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.
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:
Table - GR Study Worksheet
n X X )( XX − 2)( XX −
1
2
3
4
5
6
7
8
9
10
Tot
=×
×−
−
== 100/972.0
00.61
)(
%
2
2
Tolerancen
XX
d
MRGR
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.
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.
Table - GR&R Study Worksheet
Part Operator A Operator B Range (A-B)
1
2
3
4
5
Sum of Ranges
===∑
55)(
RRgeAverageRan
== )(33.4)( RGRRGageError
=×
==%100%)100()(
%Tolerance
GRRToleranceofaasGRR
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.
9.1 Buy-Off Form Upon completion of certification and GR/GR&R studies, a gage fixture buy-off is required. Use Form GEFM009xx supplied by Chrysler Gage Process Engineer to conduct gage buy-off.
9.2 Gage Record Book – Electronic File Structure Requirements A Gage Record book or electronic project file with like folder structure for accessing and loading of documents to Chrysler record storage location with the following information is required prior to gage fixture buy-off:
1. MEDDS Specification Detail report.
2. MEDDS Manufacturing Change Notice (MCN) report(s), if required.
3. Design Kick-Off, Review and Final Approval (Form GEFM001xx).
4. G, D & T data sheets from design file, if applicable.
5. Operation Description Sheets (ODS) for ASME / AMPS sheets for AAME CORE.
6. CMM Calibration certification for ASME. (Supplier sheet.)
7. Fixture Inspection Data results. (Also, sent to CATIA.)
8. GR / GR&R study reports (Form GEFM010 xx).
9. Tool Inspection report / Inspection data for AAME CORE, only.
10. Gage Buy-Off Form (GEFM009 xx).
11. Calibration Sign-Off (Form APFM352) for AAME CORE, only.
12. Completed Environmental form ETI-103. (Required for all programs after 2004.)
10.1 Transit Gage jack screws, legs, leveling plates, etc., shall be secured to the base for storage during transit and in such fashion to not damage checking fixture or supports. Liability is shipping originator / carrier.
10.2 Packaging All gages shall be adequately covered & protected with a minimum being skidded, lubricated and wrapped in a waterproof protective covering. The part and gage number shall be stenciled with two inch high lettering on all four sides of container or skid.
10.3 Documentation A plastic envelope shall be permanently attached to the fixture. The envelope will contain the graphic sketch showing the diamond part and its characteristics, the ODS / AMPS (covered in plastic), the part model GD&T sheet(s), if applicable, and the certification report. This documentation shall be part of the gage record at all times.
The gage fixture weight and dimensions will be stenciled / stamped on fixture for shipping. Contact Chrysler Gage Process engineer for details.
ACCURACY: Difference between the "master" or actual measurement value and that recorded by a gage.
ATTRIBUTE DATA: Qualitative data that tells only whether or not a part meets specifications.
ATTRIBUTE GAGE: Checking fixture that compares a production part to its nominal shape.
AIAG: Automotive Industry Action Group; a consortium made up of Ford, Chrysler and General Motors working with ASQC to provide guidelines for assessing the Quality of a Measurement System.
BODY-IN-WHITE (BIW): Bare metal shell of the body including doors, deck lid, front fenders and hood prior to paint and trim operations in the assembly plant.
CAD: Computer Aided Design.
CALIBRATION. Adjusting a measurement device for accuracy.
CERTIFICATION: The process of checking that a gage conforms to design and dimensional specifications including preparation of documents recording conformance.
CHECK DETAIL: Detail for verifying part to product intent.
CHECKING FIXTURES: Production inspection tools that use attribute data to evaluate parts to specifications.
CMM: Coordinate Measuring Machine.
COMPOSITE: Any material that consists of two or more components; typically one or more of high strength and one adhesive binder.
CONSTRUCTION TOOLING BALLS: Used for alignment, construction and dimensional certification.
CUBE FIXTURE, (Q) Gage: Modular checking fixture system used to hold panels for CMM inspection. The modules are assembled on a universal block known as a cube.
DATUM: A part feature that locates a part, panel or assembly, for the purpose of measuring other features on the part. The datum can be a surface, hole, slot or other feature.
DATAMYTE: Brand name for hand-held data collection device used in conjunction with variable data input devices; (e.g. hand -held transducers or encoders).
DESIGN SIDE OF METAL: The side of material that is the basis of the math data for a part.
FEELER CHECK: Gap check of a part to a checking fixture detail.
FT GAGE: Flexible Tooling checking fixture for DEA system 5..
GAGE R&R: Gage repeatability and reproducibility.
GD&T: Geometric Dimensioning and Tolerancing; a method of identifying critical dimensions on a part drawing by means of a standard set of symbols.
(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.
The following list shall be used for all fixtures at Chrysler user run plants.
Any gage design/build source NOT on the following list requires Chrysler Gage Committee waiver approval prior to sourcing of gage fixture work. (Request blank Waiver form STFM005xx from Gage Process engineer for filing approval determination of non-approved selection.)
12.1.1- A. Approved Source List - Gage Design and Build
List SUPPLIER: ADDRESS PHONE NO.# SUPPLIER
CODE NO.#
A. FUTURAMIC 24680 Gibson Drive
Warren, MI 48092 586-758-2200 586-497-8850
38454 Design & Build.
A. JAY ENN CORP. 33943 Dequindre Rd.
Troy, MI 48084 248-588-2393 53393 Design & Build.
A. METRO TECHNOLOGIES Ltd.
1462 East Big Beaver Road Troy, MI 48083-1904
248-528-9240 96145 Design & Build.
A.
STANDARD COMPONTENTS, Inc.
44208 Phoenix Drive Sterling Heights, MI 48314
586-323-9700 77457 Design & Build.
A. SHARP MODEL CO.
70745 Powell Road Romeo, MI 48065
586-752-3099 52186 Design & Build.
A. SMITH BROTHERS TOOL
50600 Corporate Drive Shelby Twp., MI 48315
586-726-5756 54537 Design & Build.
A. SPEC TECHNOLOGIES, Inc.
51455 Schoenherr Road Shelby Twp., MI 48315
586-726-0000 40750 Design & Build.
SECTION 12.1.1
NOTE: A. Any SECTION 12.1.1 A. supplier may also provide either Design or Build separately.
12.2.1 B. Approved Source List - Gage Design and Build
The following approved source list, should be used for outside supplier gages. If a supplier selects a source that is not on the approved source list, then the supplier shall notify the Chrysler Gage Process Engineer for waiver approval. (Refer to Gage Standards Appendix "A").
B. VALIANT Machine Tool & Gage (aka GLOBAL I.E.M., Inc.)
6465 Hawthorne Ave. Windsor, Ont. N8T 3G6
519-974-5200 36567 Design & Build.
12.2.2 B. Approved Source List - Gage Design ONLY
NOTE: Any SECTION 12.2.1 B. supplier may also provide either Design or Build separately.
12.3.1 C. Approved Third Party Verification List
The following Third Party Verification source list, should be used for verification of another supplier source's gage. The Third Party Verification supplier shall NOT have a vested interest in the design / build of gage being verified. If a supplier selects a source that is not on the approved source list, then the supplier shall notify the Chrysler Gage Process Engineer for waiver approval.
SECTION 12.3.1 NOTE: THIRD PARTY Certification requirements apply for Chrysler Group Assembly Plant Gages ONLY.
A. Third party as applied to Section 12.1.1-A Design & Build Suppliers:
1. Third party certification NOT required for Chrysler end item gages. 2. Third party certification NOT required for all tier 1 & 2 supplier gages.
B. Third party as applied to Section 12.2.1-B Design & Build Suppliers:
1. Third party certification is required for ALL Chrysler supplier gages. 2. Third party certification must be completed by "12.3.1 C. Approved Third Party Verification List" supplier listed in current release of GEDOC001 Chrysler AME/ASME Gage Standards.
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. Product Supplier develops a Timing & Progress schedule for designing & building of gages and documents issues, resolutions, etc., with meeting minutes.
2. The Product Team approves the datum scheme for the gage. 3. 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.
4. 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. The design is to include all the necessary views & sections to show gage functionally. 2. The design is to incorporate all requirements within these Gage standards 3. 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. 4. Chrysler AME/ASME Gage Process Engineer will issue the Gage Design Approval Form
(GEFM001), with a 40% design review sign-off.
C. 90% / 100% Review:
1. The completed design is to identify all G, D & T and all checks. 2. Confirm that all changes requested by the team at the 40% design review are completed. 3. All design title blocks are to contain the following information:
a. Chrysler Gage number. b. Part Number & change level. c. Model year & body style.
d. Part name. e. Supplier Name. f. Design & Build source name.
4. All designs to include an Operation Description Sheet (ODS). 5. Chrysler AME/ASME Gage Process Engineer will re-issue the Gage Design Approval
Form (GEFM001 xx), and will sign for 100% design approval. (Note: This is the suppliers authorization to begin build.) - Attendance for Chrysler AME/ASME Gage Process Engineer, Product Engineer and Design source representative required to hold design review meeting . - Signature approvals from the Chrysler AME/ASME gage Process Engineer and Product Engineer required.
5. Chrysler AME/ASME Gage Process Engineer to enter all information into the Chrysler fixture tracking system "EnGage".
6. Gage manufacturer begins build NC cutting fixture to latest Product model. 7. Gage fixture supplier to create a CMM Inspection Program. (Ref. Gage Standard Chapter 7.) 8. 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.
9. Gage fixture supplier to send Inspection Data to the Team Leader. Data must include:
A. Graphic that identifies all points checked. B. Nominal dimension, measured dimension, deviation of each point, and surface I, J, K vectors.
C. Part Number. D. 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. Graphic identifying all points checked. B. Nominal dimension, measured dimension, deviation of each point, and surface I, J, K vectors. C. Part Number. D. Part Engineering Change (E/C) Level.
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, 84-206-0021.)
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. Signed Gage design approval forms. B. GD&T sheets. C. Operation Description Sheets (ODS). D. Inspection data & road map. E. CMM fixture alignment report. F. GR / GR&R reports. G. Tool Inspection Report. H. Print of the gage design and stock list.
I. CATIA print of the latest product model. J. Third Party Audit Report.
(NOTE: These all may be supplied in the Process Sign-Off (PSO) book.)
16. Gage Process Engineer will issue a Gage Buy-off form (GEFM009 xx).
17. Upon final approved certification, Gage Process Engineer will issue a Chrysler Gage Certification Tag, 84-206-0020.
(NOTE: The Gage fixture supplier will stamp the required information on the tag, as directed by the Chrysler AME/ASME Gage Process Engineer.)
18. Chrysler AME/ASME Gage Process Engineer finalizes all information into the Chrysler fixture tracking system "EnGage". This consists of the following: A. Input of Certification Data. B. Input of GR&R study report data. 19. The gage fixture is the property of Chrysler. The gage fixture supplier along with the Chrysler Product Engineer is responsible for keeping the gage fixture current to the latest data level by the following tasks: A. All design changes are to be documented on the gage design and approved by the Chrysler AME/ASME Gage Process Engineer. B. All fixture changes made are to be certified and documented on the fixture attached Chrysler Gage Certification tag, 84-206-0020.
B.1. General a. All soft/hard trim Gages to be constructed per current release of AME/ASME Gage Standards
and the following guidelines. b. All suppliers’s to follow procedure's as outlined in Gage Standards Appendix A.
B.2. Datums a. Functional datums (where mating part would support) can also be used (Per approval of the
Product Team. See Gage Standards Appendix A.) b. All functional datums must be able to swing clear of part.
B.3. Swing Templates a. Swing templates simulating the mating part are to be used at all significant "Gap" areas. b. Swing templates can also duplicate as functional datums.
B.4. Materials a. Recommended build material is die planking. b. Recommended composite type check fixtures to be made of 60% carbon fiber and 40% epoxy. c. Build material to be approved by the product team.
B.5. Statistical Process Control (SPC) a. Fixed scales may be used for collecting variable data. All variable data collecting devices must be
approved by the product team.
B.6. Grid Lines a. Grid lines are to be incorporated in all soft trim tub gages every 200mm (F/A direction only). b. Grid Lines are to be used for reference only.
B.7. Tolerancing a. 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.
B2.1.0 GENERAL Appendix B is not intended to be used for production gages.
It is not to be used for SO gages that will be used for production (production pull ahead gages). It is intended for S0 program gages only.
B2.1.1 Sourcing
Detail check gage will be placed with the soft tool stamping source and be built by a Chrysler approved gage source.
B2.1.2 Design
A gage concept drawing or CAD model shall be submitted to and approved by the Chrysler Dimensional Control Team prior to the construction of the fixture.
The drawing shall define a male or a female representation, and show part orientation. The drawing shall indicate the position of the locators, datums, and bases.
Bases shall be called out on whole body grid lines i.e. 100X, 275Y, and 325Z. Rails, pin checks, sight checks, clear surfaces and clamps shall be shown.
The clamping sequence shall be identified.
Supplier shall include a protected copy of the G, D & T sheets (in a plastic sleeve, three ring binder, etc.) pertaining to the subject part.
B2.1.3 Construction
Fixtures shall be constructed from a stable material which has minimal dimensional movement due to environmental changes. (Reference Gage Standards Section 6.2, Datums)
Fixtures shall allow access for feeler gages in areas identified as feeler check surfaces.
Fixtures shall allow access for CMM measurement at locations identified as CMM measurement points.
All datum pads shall be constructed from brass or cold rolled steel. Chrysler supplied G, D & T sheets will determine the location of the datums.
Unless otherwise specified, a datum size of 25.00 mm square will be considered standard.
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.
Locating pins shall be in accordance with the part model GD&T sheet.
Trim lines shall be checked in accordance with supplied GD&T sheet. A machined flush check is required for all trim edges. A scribe line check may also be acceptable with approval of the Chrysler Dimensional Control Team.
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.
Pins shall be certified by locating a minimum of three (3) equally spaced points around the diameter of the pin to determine centerline relative to master datums.
B2.1.8 Repeatability Certification
The gage supplier will contact the Chrysler Dimensional Control Team to oversee a fixture repeatability study (GR) prior to part shipment to Chrysler.
B2.1.9 Certification Data
The gage supplier shall have certification data containing the component name, component part number, engineering change level, design check point data and measured data (actual) for review by the Chrysler Gage Process Engineer.
B2.1.10 Identification Tag
A metal tag (84-206-0020) will be supplied by Chrysler Gage Process Engineer and secured to the fixture with the part name, part number, engineering change level, certification date and fixture fabricator by the gage supplier.
This appendix standard provides a common NON-CONTACT GAGING standard for use with a dimensional control strategy using non-contact three-dimensional (3-D) measurement technology, for use by Chrysler Engineering Departments except Power Train Engineering.
C.0.1 Non-Contact Gaging Requirement This standard gives the non-contact gage engineering source guidance in the design, build, inspection and certification of non-contact gage fixtures and for applying optical measurement to inspect closure assembly product components.
C.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 uniform application of optical gages for product components supplied to Chrysler.
C.0.3 Deviation to Standard Written request for waiver or deviation from these standards will be reviewed by the Chrysler Gage Process engineer. An approved request will be included along with the standard as supplement part of the specification package.
C.0.3.1 Quotation Requirement All quotations shall state that the non-contact gage fixture being quoted will be designed and built to the specification package and/or Chrysler/Chrysler Group Non-Contact Gaging Standard plus supplements.
C.0.4 Authorization Qualifications Authorization of a non-contact gage application shall not constitute a waiver or guarantee of responsibility for any non-contact optical gage measurement equipment purchased by Chrysler Corporation. An approved non-contact gage fixture design does not constitute a certified or functional optical gage.
C.0.5 Non-Contact Gaging Environment Non-contact gages must be capable of operating in either a clean environment or manufacturing environment and are not intended to be used as qualifying tools or weld fixtures during product build.
C.0.6 Build Sources Chrysler approved/recommended design/build sources shall be used unless prior approval is given by the Chrysler Gage Process engineer.
(Reference GEDOC001 Chapter 12.)
C.1.0 OPTICAL GAGING Fixture Design
C.1.1 General – Design Property (Apply GEDOC001 Chapter 2.1.1.)
C.1.3 Kick-off, etc., Meetings Chrysler Gage Process engineer will conduct a design kick-off/ review/ approval meeting with the non-contact gage fixture supplier/ manufacturer prior to the construction of the holding fixture.
C.1.3.1 Design Release All non-contact gage designs shall be signed-off by Chrysler Gage Process engineer using the Gage Design Kick-off, Review, and Approval form (GEFM001 xx) supplied by Chrysler Gage Process engineer.
A. Magnetic nets are acceptable. Clamping requirement determined by Gage Process Engineer, as product’s need arises.
B. Non-contact gage fixtures shall allow access into areas identified as measurement point and feature checks.
Minimum clearance parameters for a specific non-contact optical measurement equipment type will be detailed in the program’s specification documentation
C. If there are NO locating holes, other selected datums will be agreed upon with Gage Process Engineer.
C.1.8 Alignment Features (Apply GEDOC001 Chapter 2.2.2.)
A. Common alignment methods include using 3-2-1, hole, slot and surface points, and alignment by edge points and surface points. The fixture should allow measurement access to these critical features.
C.1.9 Part Orientation
The non-contact gage fixture design shall default to body position for part orientation. Orientation in an out-of-body position is by Gage process engineer approval only.
C.1.10 Base Call out
Bases shall be aligned to whole body grid lines i.e. 100X, 275Y, and 325Z.
C.2.0 Non-Contact GAGING Fixture Construction (Apply GEDOC001 Chapter 6.0.)
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.
Locating pins shall be in accordance with the part model GD&T sheet. Go / No-Go size pins are required for PLP hole inspection, unless otherwise specified by Chrysler Gage Process engineer for program.
C.2.6 Clamping (Apply GEDOC001 Chapter 6.3.)
Apply Magnetic Nets which must have a holding force of 20 pounds minimum.
Operation Description Sheets required with each non-contact gage fixture describe the initial set-up of checking fixture, the loading of the part, the sequence of operation and clear instructions for all feature inspections.
C.2.8 Color Consideration
Improved optical contrast for a non-contact gage fixture must be considered in design and build. Black matte fixture surfaces reduce reflectivity and improve imaging.
C.3.0 Non-Contact GAGING Fixture Certification
C.3.1 CMM Inspection Data of Optical Gage Fixture
The non-contact gage fixture supplier shall verify CMM inspection data to the latest product CATIA model. A second party (not the author of the CMM check program) shall perform the verification. This can be done internally by the gage manufacturer or by an outside third party source. (Reference GEDOC001 Chapter 7.)
C.3.2 Requirements for Certification & Calibration
Non-contact gage fixture supplier shall adhere to the requirements for certification and calibration as stated in Element 4.10, Inspection and Testing and Element 4.11, Control of Inspection, Measuring, and Test Equipment in the QS-9000 manual.
C.3.3 Inspection Point Spacing
(Apply GEDOC001 Chapter 7.2.)
C.3.4 Generating Inspection Points (Apply GEDOC001 Chapter 7.2.3; OMITTING Items B., C., D., E., & F. from GEDOC001 Chapter 7.2.3 for this Optical Gage fixture.).
C.3.5 Certification (Apply GEDOC001 Chapter 7.3.)
C.3.6 Tolerances for Checking Fixtures (Apply GEDOC001 Chapter 7.4.1. Apply to features callout)
C.3.7 Gage Repeatability/Gage Repeatability and Reproducibility (GR/GR&R)
Apply non-contact optical measurement system equipment as alternate method of collecting part data for GR study, 1 operator with same part ten (10) times, and GR&R study, 2 operators with same part five (5) times, using non-contact gage fixture for product support.
(Reference GEDOC001 Chapter 8.0. for data criteria.)
C.4.0 Non-Contact GAGING Fixture Buy-off and Shipping
C.4.1 Buy-off Form (Apply GEDOC001 Chapter 9.1)
C.4.2 Document Required at Buy-Off
1. Current GD&T sheets from design file.
2. Operation Description Sheets (ODS).
3. CMM Calibration certification.
4. Fixture Inspection Data results. (Also, sent by CATIA.)
5. GR/GR&R study report.
All supplier generated documentation to be electronically delivered to the Gage Process engineer in a printable format.
C.4.3 Fixture Data
A plastic envelope shall be permanently attached to the gage fixture. The envelope will contain the ODS (covered in plastic), the part model GD&T sheet(s), and the certification report. This documentation shall be part of the fixture at all times.
C.4.4 Gage Delivery
Non-contact gage fixture suppliers are responsible to deliver the gage fixture to the location of the final user in the same condition as recorded at the time of non-contact gage fixture buy-off.
C.5.0 OPTICAL GAGING Application for Product Validation
C.5.1 Validation Criteria
Follow MQGR (90-Series) Procedure, 90-67xx, Dimensional Buy-Off Procedure for Upgrading Stamped Parts During Die/Tool Development, supplied by Die or Tool Process engineer, as specified at issue time of purchase order.
In each stage, the responsible non-contact optical measurement system equipment REPORT supplier shall verify in written report, in conjunction with the Buyoff Team, the level of quality as compared to each interim target, analyze causes for non-conformance, determine appropriate counter measures and submit results to Chrysler Process engineer. Slightly different target quality requirements may be established to recognize the distinction among closure panels and body-in-white/dimensional parts as well as the stages of development.
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.)
D.1.0 S0 Gage Design
D.1.1 General – Design Property (Apply GEDOC001 Chapter 2.1.1.)
D.1.2 S0 Gage Design S0 gage designs shall be a Computer Aided Design (CAD).
D.1.3 Kick-off, etc., Meetings Chrysler Dimensional Control Team will conduct a design kick-off/ review/ approval meeting with the S0 gage supplier/ manufacturer prior to the construction of the fixture.
D.1.3.1 Design Release All S0 gage designs shall be signed-off by Chrysler Dimensional Control Team using the Gage Design Kick-off, Review, and Approval form (GEFM001 xx) supplied by CHRYSLER Dimensional Control Team.
D.1.5 Material Thickness (Apply GEDOC001 Chapter 2.1.10.)
D.1.6 Design Considerations (Apply GEDOC001 Chapter 2.1.11; OMITTING items C. & D.)
A. Operator and maintenance personnel safety.
B. Simplicity in operator part loading without restrictions or interferences.
D.1.7 Design Layout Requirements: Base Orientation (Apply GEDOC001 Chapter 2.2.1.)
D.1.8 Alignment Features (Apply GEDOC001 Chapter 2.2.2.)
D.1.9 Part Orientation The S0 design shall define a male or a female representation, and show part orientation. The drawing shall indicate the position of the locators, datums, and bases.
D.1.10 Base Call out Bases shall be called out on whole body grid lines i.e. 100X, 275Y, and 325Z. Rails, pin checks, sight checks, clear surfaces and clamps shall be shown.
D.1.11 Clamping Sequence The clamping sequence shall be identified.
D.2.0 S0 Gage Construction
D.2.1 Base S0 Fixture Bases should be made of cast aluminum or 1” aluminum tooling plate. This is required to avoid warping. The fixture base size should be approximately 250 mm larger than the periphery of the part.
D.2.2 Gage Materials S0 Gages shall be constructed from red or gray REN plank. They must be handled, used and stored in a manor appropriate for precision tools.
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.
D.2.6.2 Pin Bushings All S0 gage pins shall slip fit into standard size bushings. The bushings shall be press fit in nominal position in
the gage. Lock-Tite material is not allowed.
D.2.6.3 PLP pins’ size and configuration (Refer to GEDOC001 Figure 6.4c, 6.4d.)
D.2.6.4 Holes with Positional Tolerance 1.0mm or less (Apply GEDOC001 Chapter 6.4.2.)
D.2.6.5 Holes with Size Tolerance 0.25mm or less (Apply GEDOC001 Chapter 6.4.4. See GEDOC001 Figure 6.4a) D.2.6.6 Checking Hole Locations (Apply GEDOC001 Chapter 6.4.5 See GEDOC001 Figure 6.4.a
D.2.6.7 Gage Pin Examples: (See GEDOC001 Figure 6.4a through 6.4f.)
D.2.7 Trim Check Trim lines shall be checked in accordance with supplied GD&T sheet. A machined flush check is required at all trim edges. (See Figure D.2.B.) A scribe line check may also be acceptable with approval of the Chrysler Dimensional Control Team.
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.
D.3.0 S0 Gage Certification
D.3.1 CMM Inspection Data The S0 Gage Supplier shall verify CMM inspection data to the latest product CATIA model. A second party (not the author of the CMM check program) shall perform the verification. This can be done internally by the S0 Gage Manufacturer or by an outside third party source. (Reference GEDOC001 Chapter 12.)
D.3.2 Requirements for Certification & Calibration S0 Gage Supplier shall adhere to the requirements for certification and calibration as stated in Element 4.10, Inspection and Testing and Element 4.11, Control of Inspection, Measuring, and Test Equipment in the QS-9000 manual.
D.3.3 Inspection Point Spacing (Apply GEDOC001 Chapter 7.2.2.)
D.3.4 Generating Inspection Points (Apply GEDOC001 Chapter 7.2.3; OMITTING Items B. & C. for S0 Gage fixtures.)
A. Net Blocks - generate a minimum five (5) points; one (1) at each corner and center. (OMIT Items B. & C. from GEDOC001 Chapter 7.2.3 for S0 Gage fixtures.)
D. Template (contour edge) - make two (2) rows of data; 1mm from each side of blade.
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 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 nominal to part surface.
D.3.8 Approved certification tag (Apply GEDOC001 Chapter 7.3.5.)
D.3.9 S0 Supplier CMM Data All S0 Gage suppliers must be capable of sending CMM data to Chrysler SPC database through web based CMM upload interface.
D.3.10 Certification inspection data (Apply GEDOC001 Chapter 7.3.7.)
D.3.11 Tolerances for Checking Fixtures (Apply GEDOC001 Chapter 7.4.1.)
D.4.0 S0 Gage Buy-off and Shipping
D.4.1 Buy-off Form (Apply GEDOC001 Chapter 9.1.)
D.4.2 Document Required at Buy-Off
1. Design Kick-Off, Review and Final Approval (Form GEFM001 xx, supplied by CHRYSLER Dimensional Control Team).
2. G,D&T data sheets from design file, if applicable.
3. Operation Description Sheets (ODS).
4. CMM Calibration certification.
5. Fixture Inspection Data results. (Also, sent by CATIA.)
6. GR study reports (Form GEFM010xxGR, supplied by CHRYSLER Dimensional Control Team). Refer to the detail process of GR in Appendix 11.6 of CHRYSLER Dimensional Quality Plan.
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.
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. Supplier’s 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. Supplier’s 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:
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.)
