Process+Control+Plan

JOHNSON ELECTRIC INDUSTRIAL MANUFACTORY LIMITED

PROCESS CONTROL PLAN

CONTROL PLAN TYPE :[ ] PROTOTYPE[ X ] PRE-LAUNCH[ ] PRODUCTION

PROCESS CONTROL PLAN NO 1030126REV.

FIRST ISSUE DATE :8 Aug 05REVISED DATE :

JE PART NO./ REV NO. :1999-1030126EP/ B CUSTOMER PART NO./REV NO.:

PART NAME /DESCRIPTION Motor Assembly CUSTOMER NAME JE France SAS SUPPLIER CODE :SUPPLIER / PLANT JE / AUTO / Q&R JE DOC NO. :DBBBB-CP-1030126 0

EXTERNAL KEY CONTACT (Sales) :INTERNAL KEY CONTACT (QA) :Xiaoe Mao

CORE TEAM :WY Kong (EAT), Lawrence Wu (EVA), Xiaoe Mao (QA), CK Auyoung (PE)

REMARK : 1. Reaction plan for out of control - unless specified hold the lot processed between the previous interval's assemblies

and upto the time the problem is discovered. Consult QC and production supervisor for disposition and investigation.

2. Unless otherwise specified, set up verification is required for all processes in accordance with CCTBF-SP-0000001.

3. Reason of change : According to CRRN NO 3F/16360 change rear housing & endcap and balancing method.

TOTAL PAPER NUMBER : 12pages (including this cover page)

JEI APPROVAL

APPROVED BY (ON BEHALF OF THE CORE TEAM MEMBERS) :

Xiaoe Mao

OTHER APPROVAL (IF REQ'D)

CUSTOMER QUALITY APPROVAL / DATE :CUSTOMER ENGINEERING APPROVAL / DATE :

OTHER APPROVAL / DATE :

PROCESS CONTROL PLAN

Control Plan Number :1030126Rev. :1Page 2 of12 Part / Process Name / Machine, Device,Characteristics Special Method

Process Operation Jig, Tools No.Product Process Char.Product / Process Evaluation Sample Control Reaction Number Description For Mftg.Class Specification / Tolerance Measurement Technique Size Freq.Method Plan All raw Material receiving Check test data of vendors's supplied document w.r.t IICL (Incoming Inspection Check List ) IQC report Issue mat'ls DMN (Refer BOM)Refer to CCHQD-SP-0000003 for detail

Commutator Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPCMPH305/2CPCMPH305/2DMN Bushing Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPSBBD350/85CPSBBD350/85DMN

Bushing Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPSBFDF351/4/85CPSBFDF351/4/85DMN Magnet holder Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPMHPC3110CPMHPC3110DMN

Ring varistor Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPVRCE3170/2CPVRCE3170/2DMN Spacer Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPSPBR228X400CPSPBR228X400DMN

Carbon brush Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPCBCG341/3CPCBCG341/3DMN Capacitor Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPCPMC330x003CPCPMC330x003DMN

Magnet Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue CPPMSF336CPPMSF336DMN 2-EIW Magnet wire Material receiving Inspect w.r.t. to IICL (Incoming Inspection Check List )IQC report Issue 0060-1040210-10060-1040210-1DMN

Control Plan Number :

1030126

Rev. :

Page 3 of 12

Part / Process Name / Machine, Device,

Characteristics Special

Method Process Operation Jig, Tools No.

Product Process

Char.Product / Process Evaluation

Sample Control

Reaction Number Description

For Mftg.

Class

Specification / Tolerance

Measurement Technique

Size Freq.

Method Plan 1121-1030072Refer to Issue Epoxy coated Stacking & epoxy 1121-1030072

C&S OIR

QNCR

arm.ass'y coating 37210-10900Stamping

Refer to Issue Slinger

37210-10900

C&S OIR QNCR

35030-11000Stamping

Refer to Issue Washer

35030-11000C&S OIR QNCR

35040-11000Stamping

Refer to Issue Washer

35040-11000C&S OIR QNCR

1101-1030006Shaft production

Refer to Issue Motor shaft

1101-1030006C&S OIR QNCR

31000-10200Stamping

Refer to Issue Lamination

31000-10200C&S OIR QNCR

31100-30100Drawing

Refer to Issue Rear housing

31100-30100C&S OIR QNCR

31100-20100Injecting molding

Refer to Issue End cap

31100-20100C&S OIR QNCR

31100-27100Stamping

Refer to Issue Terminal holder

31100-27100C&S OIR QNCR

Refer to the Basic control plan of Refer to the Basic control plan of Refer to the Basic control plan of Refer to the Basic control plan of Refer to the Basic control plan of Refer to the control plan of Refer to the Basic control plan of Refer to the Basic control plan of Refer to the Basic control plan of

Control Plan Number :

1030126

Rev. :

Page 4 of 12

Part / Process Name / Machine, Device,

Characteristics Special

Method Process Operation Jig, Tools No.

Product Process

Char.Product / Process Evaluation

Sample Control Reaction Number Description For Mftg.

Class

Specification / Tolerance

Measurement Technique

Size Freq.

Method Plan 34900-20400Sintering

Refer to Issue Bushing retainer

34900-20400

C&S OIR

QNCR

32250-20500Stamping

Refer to Issue Terminal

32250-20500C&S OIR QNCR

32800-25356Heat treated

Refer to Issue Heat treated 32800-25356C&S OIR QNCR

brush leaf 33100-10800Stamping

Refer to Issue Spacer

33100-10800C&S OIR QNCR

31100-11000Stamping

Refer to Issue Bushing washer

31100-11000C&S OIR QNCR

31100-30800Forming

Refer to Issue Spring

31100-30800C&S OIR QNCR

Part / Process Name / Machine, Device,Characteristics Special Method

Process Operation Description Jig, Tools No.Product Process Char.Product / Process Evaluation Sample Control Reaction Number For Mftg.Class Specification / Tolerance Measurement Technique Size Freq.Method Plan A01Apply epoxy glue to Apply epoxy Nil Nil

stack glue tools

A02Fit commutator Fit commutator Comm angle12° ± 2°Angle gauge 2 pcs Half a shift Check sheet Refer to to stack fixture note 1

on cover

Armature length and46.20 ± 0.10mm Fixture w/ dial 2 pcs Half a shift Check sheet Refer to

Ef indicator note 1

on cover A03Epoxy glue curing Tunnel oven Curing time15 ± 3minutes Timer Once Per shift Check sheet Refer to

note 1

on cover

Comm. Push off45 kg min Pushing meter 2 pcs Half a shift Check sheet Refer to

force note 1

on cover

Curing temperature150° ± 10°C Thermometer Once Half a shift Check sheet Refer to

note 1

on cover A04Armature Winding Winding machine Appearance No wire loose.bulky &Visual inspection 5 pcs 2 hrs Check sheet Refer to

damaged. No epoxy note 1

chipped & lam. shift on cover

Winding method A18Visual inspection Once Per m/c Check sheet Refer to

set up note 1

on cover

Winding 190-210 DG Pulling tester Once 2 hrs Check sheet Refer to

tension Change felt/note 1

magnet wire on cover

No. of turns163Unwinding1pc Half a shift Check sheet Refer to

note 1

on cover

Winding height7.53 mm min Caliper 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Part / Process Name / Machine, Device,Characteristics Special Method

note 1

on cover

Comm TIR30m m max TIR meter 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Appearance No poor fusing Visual inspection5pcs 2 hrs Check sheet Refer to

note 1

on cover A06Check armature resistance Ohmmeter Resistance 3.37-3.73 Ohm Ohmmeter 100%Continuous Defect record Refer to

2 pcs Per shift Check sheet note 1

on cover

Tester ± 1 %Resistance gauge Once Half a shift Check sheet Refer to

check note 1

on cover A07Fit spacer Fit spacer fixture Spacer squareness0.03 mm max Squareness meter 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Spacer push-off10.0 kg min Pushing meter 2 pcs Half a shift Check sheet Refer to

force note 1

on cover A08Solder varistor ring Soldering fixture Varistor height8.0 mm min Height meter 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Soldering335 ± 15° C Thermometer Once Half a shift Check sheet Refer to

temperature note 1

on cover A09Flux cleaning Cleaning m/c Nil Nil

A10Armature negative Balancing machine Armature balance400 mg-mm max Balancing machine100%Continuous Operator check Refer to balancing note 1

on cover A11Check varistor function Varistor tester Varistor function8 - 10 V Varistor tester100%Continuous Defect record Refer to

note 1

on cover

Part / Process Name / Machine, Device,Characteristics Special Method

note 1

on cover

Comm diameter? 5.9mm min Caliper2pcs Half a shift Check sheet Refer to

note 1

on cover

Comm TIR10m m max Roundness tester2pcs 2 hrs Check sheet Refer to

note 1

on cover

Comm bar to bar6m m max Roundness tester2pcs 2 hrs Check sheet Refer to

note 1

on cover

Comm. Roundness Roundness tester2pcs 2 hrs Check sheet Refer to

note 1

on cover

No of cutting threads600 ± 60 lines/inch Surface texture tester2pcs 2 hrs Check sheet Refer to

note 1

on cover

Surface finish RZ 3.0 - 4.8 m m Surface texture tester2pcs 2 hrs Check sheet Refer to

note 1

on cover

Shaft TIR60m m max TIR meter2pcs 2 hrs Check sheet Refer to

note 1

on cover A13Wipe copper chips 1 Toothbrush Appearance No copper chips Visual inspection100%Continuous Operator check Refer to with inspection 2 Magnifer note 1

3 Inspection fixture on cover A14Visual inspection By hand Appearance No wire loose, bulky Visual inspection100%Continuous Defect record Refer to

No shaft scratched note 1

No poor soldering on cover A15Fit slinger & washers Slinger box Nil Nil

A16Hi-pot Test Hi-pot tester Current leakage500 V AC 500m A max Hi-pot tester100%Continuous Defect record Refer to

for 1 sec.note 1

on cover

Control Plan Number :1030126Rev. :1Page8 of12 Part / Process Name / Machine, Device,Characteristics Special Method

on cover

Bushing ID f 2.308+0.003/-0mm pin gauges 2 pcs 2 hrs Check sheet Refer to

f 2.308 mm GO note 1

f 2.311 mm NG on cover

Bushing push off force25 kg min Pushing tester 2 pcs Half a shift Check sheet Refer to

note 1

on cover E'01Terminal and brush Riveting fixture Riveting resistance0.50 mOhm max.1A constant current 2 pcs Half a shift Check sheet Refer to leaf riveting meter+voltmeter note 1

on cover

Riveting pull off force 2.0 kg min.Pulling tester 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Appearance No separated Visual inspection 5 pcs 2 hrs Check sheet Refer to

No deformed note 1

on cover E'02Bend tension angle on Bending fixture Brush leaf angle70 ° ± 2°Projector 2 pcs Half a shift Check sheet Refer to leaf assy'note 1

on cover E'03Fit carbon brush Fit carbon brush Carbon brush and 5 mOhm max.1A constant current 2 pcs Half a shift Check sheet Refer to fixture leaf contact resistance meter+voltmeter note 1

on cover

Carbon brush push off 1.0 kg min.Pushing tester 2 pcs Half a shift Check sheet Refer to

force note 1

on cover E'04Fit leaf assy to holder End cap assembly Nil Nil

fixture

E05Terminal riveting Riveting fixture Brush leaf pressure70 ± 10 gms Tension meter 2 pcs Half a shift Check sheet Refer to

note 1

on cover

Terminal push-off 10 kg min.Pushing tester 2 pcs Half a shift Check sheet Refer to

force note 1

on cover E'06Capacitor forming & Forming capacitor Nil Nil

trim excessive legs fixture

Control Plan Number :1030126Rev. :1Page 9 of12

Part / Process Name / Machine, Device,Characteristics Special Method

E'08Trim excessive legs Forceps Nil Nil

E'09Visual inspection By hand Appearance No missing parts Visual inspection100%Continuous Defect record Refer to

No deformation note 1

on cover R01Fit magnets & magnet Fit magnets fixture Rear housing f17.4 mm min. f 17.4 mm GO gauge 2 pcs2hrs Check sheet Refer to holder & spring to rear I.D.note 1 housing on cover R02Apply epoxy glue to Apply epoxy glue Epoxy name3M RMEPGL 2216Visual inspection Once set up Check sheet Refer to magnet and spring tools note 1

on cover R03Epoxy glue curing Tunnel oven Temp110 ± 10 °C Thermometer Once Half a shift Check sheet Refer to

note 1

on cover

Time25 ± 1 minutes Timer Once Per shift Check sheet Refer to

note 1

on cover R04Fit bushing & bushing Fit bushing fixture Bushing 200 ± 100g-cm Tension meter 2 pcs Half a shift Check sheet Refer to retainer to rear housing swivel torque note 1

on cover

Bushing I.D.?2.310 - 2.315 mm Pin gauge 2 pcs 2 hrs Check sheet Refer to

f 2.310 mm GO note 1

f 2.315 mm NG on cover

Bushing 41.00 ± 0.10mm Depth micrometer 2 pcs 2 hrs Check sheet Refer to

depth note 1

on cover R05Suction clean rear Vacuum cleaner Nil Nil

housing

R06Magnetization Charging fixture Gauss value1150 ± 5% Gauss Gauss Meter 2 pcs 2 hrs Check sheet Refer to

note 1

on cover

Polarity Negative Gauss Meter once Half a shift Check sheet Refer to

note 1

on cover

Control Plan Number :1030126Rev. :1Page 10 of12

Part / Process Name / Machine, Device,Characteristics Special Method

2. Test fixture note 1

3. Performance tester on cover

Free load current0.143A max Ammeter5pcs 2 hrs Bar X-R Chart Refer to

(CW & CCW)note 1

on cover

Free load speed4800-5500 rpm Tachometer5pcs 2 hrs Bar X-R Chart Refer to

(CW & CCW)note 1

on cover

136.3 g-cm current0.60-0.84 A Ammeter5pcs 2 hrs Bar X-R Chart Refer to

(CW & CCW)note 1

on cover

136.3 g-cm speed3570-4370 rpm Dynamometer5pcs 2 hrs Bar X-R Chart Refer to

(CW & CCW)note 1

on cover

DB70 dBA max DB tester5pcs 2 hrs Check sheet Refer to

note 1

on cover

Worm hole depth 2.5 mm max Depth gauge 2 pcs Half a shift Check sheet Refer to

note 1

on cover M01Fit armature to rear Fit armature to rear Nil Nil

housing housing fixture

M02Motor assembly Ass'y fixture Nil Nil

M03Fit metal endcap to By hand Nil Nil

motor

M04Motor crimping Motor crimping m/c Crimping 30 kg min.Pushing tester 2 pcs Per shift Check sheet Refer to

push off force note 1

on cover

Control Plan Number :1030126Rev. :1Page 11 of12

Part / Process Name / Machine, Device,Characteristics Special Method

3. Performance tester on cover

B13 fan load current0.57-0.94 A Ammeter100%Continuous Defect record Refer to

note 1

on cover

B13 fan load speed3480-4300 rpm Tachometer100%Continuous Defect record Refer to

note 1

on cover

Polarity Negative Sensor100%Continuous Defect record Refer to

note 1

on cover

Waveforms No abnormal waveforms Waveform m/c100%Continuous Defect record Refer to

(6 pcs min)note 1

on cover M06Add multi-line knurls Knurling m/c Knurling position8.0 ± 0.30 mm Caliper2pcs 2 hrs Check sheet Refer to on motor shaft note 1

on cover

Knurl length10.0 ± 0.30 mm Caliper2pcs 2 hrs Check sheet Refer to

note 1

on cover

Knurling O.D.f 2.40 ± 0.04 mm f 2.44 mm GO2pcs 2 hrs Check sheet Refer to

f 2.38 mm NG note 1

gauge on cover

Motor shaft TIR120m m max TIR meter2pcs Half a shift Check sheet Refer to

note 1

on cover

Appearance No bad knurling Visual inspection5pcs 2 hrs Check sheet Refer to

note 1

on cover M07Test N/L current and 1. Power supply Test12.0 V Voltmeter Once Half a shift Check sheet Refer to rotation direction 2. Test pin voltage note 1

3. Ammeter on cover

Free load current0.143A max Ammeter100%Continuous Defect record Refer to

note 1

on cover

Direction of 'rotation C.C.W.Hand detection100%Continuous Defect record Refer to

note 1

on cover

Armature vibration No excessive vibration Hand detection100%Continuous Defect record Refer to

& popping& popping note 1

on cover

Control Plan Number :1030126Rev. :1Page 12 of12

Part / Process Name / Machine, Device,Characteristics Special Method

Process Operation Description Jig, Tools No.Product Process Char.Product / Process Evaluation Sample Control Reaction Number For Mftg.Class Specification / Measurement Size Freq.Method Plan M08Check capacitance 1.Capacitance meter Capacitance 500-1100 NF Capacitance meter100%Continuous Defect record Refer to

2.Test pin note 1

on cover M09Motor date code Printing m/c Appearance No poor printing Visual inspection100%Continuous Defect record Refer to printing note 1

on cover M10Check rear extension Fixture with dial Motor Er40.0 ± 0.30 mm Fixture with dial100%Continuous Defect record Refer to and motor endplay note 1

on cover

Motor endplay0.50 mm max Fixture with dial100%Continuous Defect record Refer to

note 1

on cover M11Check knurling OD f 2.36 mm NG gauge Knurls exist or not Exist f 2.36 mm NG100%Continuous Defect record Refer to

gauge note 1

on cover M12Visual inspection By hand Appearance No oxidized housing Visual inspection100%Continuous Defect record Refer to

No cracks glued ring note 1

Good printing on cover M13Motor packaging By hand Appearance Correct packaging Visual inspection100%Continuous Defect record Refer to

method and qty note 1

on cover Outgoing Inspect w.r.t. 1030126 FIS (Final Inspection Standard)Issue inspection ONCR