| By each of a car assembly composed of thousands of parts, all models come with constantly upgrading and characterized by mass production. During the development of new products and mass production, every car companies faces the common issues, which are how to validate the compliance of the actual parts and design data, how to ensure the dimensional stability of the main components, to ensure vehicle performance & appearance requirements.In this paper, I mainly focus on the J61 IP inspection methods study. The combined checking gauge which can measure individual component and matching different components and a Comprehensive IP cubing were first used in FCC. The new methods solved the quality control problems occurred in IP development and mass production. To solving the J61 car quality problems after mass production and the new inspection requirements, but also for the dimension requirement of the special structure, a flexible checking gauge were developed submitting the secondary use of existing development and technical upgrading, realize the size of the detection characteristics.J61 (New Mazda6) was introduced from Japan through technical cooperation. direct import, but because the Japanese principle design for the right drive, so the IP design needs to be modified to left drive for Chinese customers. In order to reduce the change cycle & save project cost, rapid prototypes were not made for design validation, it caused great difficulties to DV & the data could not be frozen. Under this background, FCC was proposing for designing a high precision and economical measurement system to ensure development process and quality after mass productionThis article includes all problems and solutions happened throughout the J61 IP program, focusing on the IP technical standards analysis and IP dimension precision analysis based on tolerance allocation. Through comprehensive technical research while reference to past experience, combine with the current manufacturing practice, the checking gauge concept was submitted and J61 gauge and cubing were developed. The J61 gauge and cubing which presided by me not only ensured the J61 IP dimension, but also saved the program cost & changed the importing situation of the large-scale cubing. The new inspection technology played an important role in J61 DV, PV mould development, process planning, product quality improvement and quality approval process. It shorted the DV cycle by 54 days, introduced 24 mould and process changes, the IP dimension qualified rated changed from 49%(DV phase) to 97%(PV phase). It was also helpful for the part quality stability control after mass production.The main study of this paper includes J61 drawing Specification classification, product positioning structures and its Realization, inspection standards and inspection module design. In FCC first IP dimension precision study implemented based on tolerance allocation methods, the relationship between the dimensional accuracy and inspection technology was analyzed. Based on above studies, the combined checking gauge which can measure individual component and matching different components and a Comprehensive IP cubing were first used in FCC.Combined with the actual production quality issues occurred on IP, the measurement methods for deep grooves, narrow hole, a large tolerance of the special structure was studied, submitted a creative idea to use flexible gauge for J61 IP program and the second development and transformation to J61 IP gauge realized. It was great useful for the IP DV, data frozen for injection mould, pre-production cycle shorten components quality improvement and whole vehicle quality stability. It is also a lesson learned for FCC future programs.During the study, I also encountered this kind of situation, that is a company is lack of uniform technical standard & design specifications & technical information; and comprehensive cubing were imported in the past long-term because China Automotive gauge study is later than and technology is fall behind than other countries.
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