Work Instructions Logistics Services Inc. – Flat Rock, MI Version: 1.1 WI-108 PCM Date: 6/17/2008

Page 1 of 4 Printed: 9/5/2008 Printed copies of this document are considered uncontrolled as of the time of printing.

Subject: This work instruction describes the process for PCM Broadcast and Sub-Assembly. Equipment:

1) Safety Vest 3) Blind audit 5) Pen/Marker 2) Safety Glasses 4) 1st piece inspection 6) Commit Log

General Requirements:

• Walking • Lifting up to 5 pounds • Inspect each part for damage. If any damage is discovered report it to your supervisor. Place the

damaged part in the designated scrap location. • Follow procedure for First In, First out (FIFO) when obtaining stock. • Report any part shortages to your team leader. • Maintain a clean work area. • Stock area properly for the next shift.

Special Requirements: • SW-01: Standardized Work Instruction for Cell Operator • SW-10: Standardized Work Instruction for Blind Audit • SW-11: Standardized Work Instruction for 1st Piece Inspection

Sequence Procedure: PCM Sub-Assembly and Broadcast Pictures 1. Retrieve the broadcast sheet from the S-11 location. 2. Pull empty broadcast dolly in to workstation. 3. Remove old dolly tags and commit sheets from pouches on dolly

and discard. 4. Enter the appropriate information on the commit log sheet (i.e. date,

dolly number, starting and ending commit numbers, etc.). 5. Before picking a part out of a container, verify a 1st Piece Inspection

has been done. If not, verify the container has been placed in the proper spot and that the correct parts are in the container. Upon verification, place a “1st Piece Inspection Form” in container; see SW-11: 1st Piece Inspection for additional information.

6. The broadcast sheet is printed in batch format. Begin the parts picking and sub-assembly process with the first part listed at the top of the sheet and work your way down the list.

7. See steps 13-32 below for sub-assembly instructions for I4 PCMs; and steps 33-53 below for sub-assembly instructions for V6 PCMs.

8. For each finished sub-assembly and broadcast, highlight or cross-out the appropriate pick code on broadcast sheet.

9. Upon completion of sub-assembly and broadcast for commit range, conduct a blind audit according to WI-24: Blind Audit Work Instruction.

10. Verify commit numbers on broadcast sheet match dolly number sign.

11. Place dolly number sign and commit sheets into pouch with dolly sign on top (facing out of pouch), see Figure 18.

12. Place sequenced dolly in the designated dolly staging area.

Figure 1: Bottom I4 bracket seated to I4 fixture on assembly table.

Figure 2: I4 control unit seated to bottom bracket on assembly table.

Work Instructions Logistics Services Inc. – Flat Rock, MI Version: 1.1 WI-108 PCM Date: 6/17/2008

Page 2 of 4 Printed: 9/5/2008 Printed copies of this document are considered uncontrolled as of the time of printing.

Sequence Procedure: PCM Sub-Assembly and Broadcast Pictures Procedure for PCM Sub-Assembly and Broadcast (I4): 13. Read broadcast. 14. Obtain two (2) brackets from stock. 15. Walk to assembly table. 16. Align and seat bottom bracket to I4 fixture on table, see Figure 1. 17. Aside top bracket and control unit to table. 18. Grasp scanner and obtain broadcast control unit from stock. 19. Scan bar code label on control unit. NOTE: If alarm sounds, you

have pick and scanned the wrong control unit. Verify broadcast, obtain correct control unit, and scan part.

20. Aside scanner. 21. Regrasp control unit and align and seat to bracket on fixture, see

Figure 2. 22. Grasp tag label from control unit and pull to remove. 23. Regrasp top bracket and align and seat to control until and bottom

bracket. 24. Affix tag label to top bracket, see Figure 3. 25. Grasp four (4) nuts. 26. Handstart one nut to each stud on the bracket/control unit

assembly, see Figure 4. 27. Grasp air tool. 28. Position air tool to nut and pull trigger to secure. Repeat for three

(3) remaining nuts, see Figure 5. 29. Aside air tool. 30. Grasp paint marker and upon visual verification of torque, mark

each bolt. 31. Grasp completed assembly and remove from table. 32. Place control unit in to correct broadcast location in dolly, see

Figure 6. NOTE: If control unit is dropped during sub-assembly or sequence process, DO NOT USE CONTROL UNIT. Obtain another control unit from stock to replace dropped part. Notify your supervisor and take dropped part to designated QC scrap dolly.

Procedure for PCM Sub-Assembly and Broadcast (V6): 33. Read broadcast. 34. Obtain V6 bracket from stock. 35. Walk to assembly table and align and seat bracket to V6 fixture on

table, see Figure 7. 36. Grasp scanner and obtain broadcast control unit from stock. 37. Scan bar code label on control unit. NOTE: If alarm sounds, you

have pick and scanned the wrong control unit. Verify broadcast, obtain correct control unit, and scan part.

38. Aside scanner. 39. Align and seat control unit to bracket in fixture. 40. Grasp two (2) nuts. 41. Handstart one nut to each bracket stud, see Figure 8. 42. Grasp air tool. 43. Position air tool to nut (A) and pull trigger to secure. Repeat for

second nut (B). 44. Aside air tool. 45. Grasp paint marker and upon visual verification of torque, mark

each bolt. 46. Obtain V6 harness from stock and swipe zero touch button. 47. Position harness clip to bracket and align and seat, see Figure 9.

Figure 3: I4 top bracket seated to bottom bracket/control unit on assembly table with label affixed to bracket.

Figure 4: Hand start one nut to each stud on I4 bracket.

Figure 5: Secure (4) nuts using air tool.

Work Instructions Logistics Services Inc. – Flat Rock, MI Version: 1.1 WI-108 PCM Date: 6/17/2008

Page 3 of 4 Printed: 9/5/2008 Printed copies of this document are considered uncontrolled as of the time of printing.

Sequence Procedure: PCM Sub-Assembly and Broadcast Pictures 48. Grasp small coupler and align and seat to control unit; push lock

down to secure, see Figure 10. 49. Grasp large coupler and align and seat to control unit; push lock

down to secure, see Figure 11a and 11b. 50. Grasp scanner and scan commit label on printer, see Figure 12. 51. Remove commit label from printer and affix to bracket. 52. Grasp completed assembly and remove from table. 53. Place control unit in to correct broadcast location in dolly, see

Figure 6. NOTE: If control unit is dropped during sub-assembly or sequence process, DO NOT USE CONTROL UNIT. Obtain another control unit from stock to replace dropped part. Notify your supervisor and take dropped part to designated QC scrap dolly.

Figure 7: V6 bracket seated to V6 fixture in assembly table.

Figure 9: Attach harness clip to bracket. Ensure that clip is fully seated to bracket.

Figure 6: PCM placement in broadcast dolly.

Figure 8: V6 control unit seated to bracket on assembly table with (2) nuts hand started to bracket studs. When secure with air tool, tighten nut A first then nut B.

Figure 10: Attach small coupler to control unit and push lock down to secure.

I4 V6

Work Instructions Logistics Services Inc. – Flat Rock, MI Version: 1.1 WI-108 PCM Date: 6/17/2008

Page 4 of 4 Printed: 9/5/2008 Printed copies of this document are considered uncontrolled as of the time of printing.

Sequence Procedure: PCM Sub-Assembly and Broadcast Pictures

Figure 11a: Attach large coupler to control unit and push lock down to secure.

Figure 11b: Coupler locks secured.

I acknowledge that I have read, been trained on, and fully understand the above work instructions and will follow them at all times unless otherwise instructed by my supervisor. _________________________________ Employee Name (Print) _________________________________ ________________ Employee Signature Date _________________________________ ________________ Supervisor Signature Date