2009 bendix ppap requirements guidelines rev 1-9-2009

Bendix Commercial Vehicle Systems LLC Supplier Quality and Development

Bendix Production Part Approval Process (PPAP)

2009 Bendix Requirements Guideline

REVISION HISTORY TABLE Revision Number: Original Issue Revision # 1 Written By: Dale Stober Ed Smith Approved By: Mike Allegrucci Mike Allegrucci Issue Date: January 23, 2004 January 9, 2009 Approval Signature:


The 2009 Bendix Requirements Guideline for PPAPs is based Automotive Industry Action Group (AIAG) PPAP Manual – Fourth Edition. Recommended A.I.A.G. Reference Manuals for this Document include: Advanced Product Quality Planning & Control Plan - APQP – Second Edition Potential Failure Mode and Effects Analysis – FMEA – Fourth Edition Measurement Systems Analysis – MSA – Third Edition Statistical Process Control – SPC – Second Edition A.I.A.G. manuals are available through www.aiag.org


Production Part Approval Process (PPAP)

Bendix Requirements Guideline (PPAP 4th Edition)

Requirement 1. Design Records:

- For proprietary components / details - For all other components / details

2. Authorized Engineering Change Documents 3. Customer Engineering approval 4. Design FMEA (Failure Mode and Effects Analysis) 5. Process Flow Diagram(s) 6. Process FMEA (Failure Mode and Effects Analysis) 7. Control Plan 8. Measurement System Analysis Studies 9. Dimensional Results

10. Records of Material / Performance Test Results

11. Initial Process Studies

12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR)

14. Sample Production Parts

15. Master Sample

16. Checking Aids

17. Customer-Specific Requirements

18. Part Submission Warrant (PSW) 19. Supplier Change Notification and Submission Requirements for PPAP



Bendix Requirements Guideline

There are currently 19 elements that are the requirements of PPAP. The intent of this guideline is to give clarification to the Supplier of what the

Bendix expectations are for each element requirement. General Comments/Suggestions: • All 19 requirements are to be addressed, regardless of level of submission. • Page 1 of the PPAP Submission Package is recommended to be an introductory page. It should include: Part Name; Part Number; Drawing Number; Engineering Change Level; Engineering Change Level Date; Supplier Name; Supplier Code; Supplier Street Address, City, State and Zip Code; Supplier Phone Number; Supplier Fax number; Customer Name (BCVS), and the using plant that the supplier is submitting the PPAP package to. • Any element requirement that is not included or does not apply is to have a

page stating such included under the appropriate tab in the PPAP submission package.

• Note that the requirements of AIAG PPAP Fourth Edition, Appendix H, applies to

BCVS products (Truck Industry-Specific Requirements). • The APQP Core Tools Forms diskette is available to guide the supplier through the

part approval process (contact your BCVS Supplier Quality Development representative).

• The supplier can expect to have the submitted PSW form, once approved by Bendix, returned to them via fax (be sure to include appropriate fax number on introduction page). • Production part approval records, regardless of submission level shall be maintained for the length of time that the part is active plus one calendar year. • All Drawings, Specs, and other supplemental information contained herein as examples, is strictly for reference purposes only.




1. Design Records: Hard copies of the following items are to be submitted with the PPAP package:

• Engineering Drawings • Process, Material and Engineering Specifications • Design Records are required for all components and details e.g. where the part is

a machined casting, the machining supplier is responsible to produce the design records for the casting, which includes the Supplier’s approved Part Submission Warrants and all Design Records for all sub-supplier parts.

• Where the design record is in electronic format, the supplier shall still provide a hard copy of those documents.

As an example, reference the Bendix prints and associated specs included in this document (element # 9, "Dimensional Results").

Note 1: For any saleable product there will be only one design record. The design record may reference other documents making them part of the design record. Note 2: A single design record can represent multiple part or assembly configurations. Note 3: For parts identified as “black box”, the design record specifies the interface and performance requirements. Note 4: For parts identified as catalog parts, the design record may consist only of a functional specification or a reference to a recognized industry standard. Note 5: For bulk materials, the design record may include identification of raw materials, formulations, processing steps and parameters, and final product specifications or acceptance criteria.

• Reporting of Part Material Composition shall be provided by the supplier when required and this data must comply with all Bendix requirements.

• Polymeric parts must be identified with the ISO symbols such as specified in ISO 11469 (Plastics) and/or ISO 1629 (Rubber & lattices). The following weight criteria shall determine if the marking requirement is applicable: - Plastic parts weighing at least 110g.

- Elastomeric parts weighing at least 220g.




2. Authorized Engineering Change Documents:

• Examples include marked up drawings signed and approved by BCVS Engineering, or MCRs where approval by BCVS Engineering has been obtained.

• PPAPs are NOT to be submitted if the design requirements have not been met.




3. Customer Engineering Approval:

• Bendix specifications may require suppliers to submit test results or samples for evaluation by the BCVS Materials Department. Suppliers are responsible for conforming to the requirements of BW specs either called out on BCVS drawings, or as included as part of the Design Record prior to PPAP submission.

As an example, reference the Bendix spec, BW-128-P, section 6.0 included in this document.

AlliedSignal AUTOMOTIVETruck Brake Systems

Elyria, Ohio 44036 U.S.A.

PROCESS SPECIFICATION BW-128-P

CHROMATE CHEMICAL CONVERSION FILM (ALODIZING)FOR ALUMINUM ALLOYS

Ralph Lennerth 12/10/99 Dave Knight 12/10/99WRITTEN DATE APPROVED DATE

REVISED SPEC. BW-128-PDATE INIT. ECN NO. 4 SHEETS

Rev. 15: 12/10/99 RJL:dah 68216 SHEET NO. 1PRODENGR FORM 003.DOC Mar. 29, 1994

1.0 SCOPE

The purpose of this process is to produce a chemical chromate conversion film onaluminum alloy parts to improve corrosion resistance and paint bondingproperties. This treatment shall be applied after all machining, stamping, bendingor other forming operations have been performed.

The coating will degrade at temperatures above 140° F (46°C) with subsequentloss of corrosion resistance.

2.0 PROPERTIES

2.1 Parts treated according to this specification shall have a uniform iridescentto brown adherent coating. A porous, powdery coating is not acceptable.The process shall supply the corrosion resistance described underQualification Requirements.

3.0 PROCESS

3.1 The parts shall be placed in baskets in a manner which will minimize airpockets and provide best drainage, when possible. Configuration of someparts may leave an unavoidable air pocket. Certain parts alodized by outsidevendors may be rack coated in which case rack marks must be in a non-critical location. Sealing ring grooves and seat areas are typical criticallocations.

3.2 If the conversion coating bath is heated, stirring is recommended to avoidbreakdown of chemicals in the immediate vicinity of the heating coils.

DOCUMENTO CONTROLADO DE FORMATO ELECTRÓNICO: Antes de utilizarlo se requiere verificar el nivel de revision o la suficiencia.CONTROLLED ELECTRONIC MEDIA DOCUMENT: Verification of revision level or adequacy is required prior to use.





SPEC. BW-128-P4 SHEETSSHEET NO. 2

3.3 The first rinse following alodizing is required to remove alodize solutionand stop the action. The second rinse is a hot water rinse required to set thealodize and produce a cure. The process is as follows:

Operation Solution Concentration Temperature TimeClean* Alkaline,

Non-etchingAs required As required As required

Rinse Cold Water -- Room VariableAlodine** Alodine 1600 (by volume)

0.83 oz./gal 1.5 – 2.0 pH

60-130° F 1-5 Min.

Rinse Cold Water -- Room VariableRinse Hot Water -- 180°F Max. Variable

* This cleaning step may be omitted for castings coming directly from thePlastic Impregnation Processing Line as the castings have already beenthoroughly washed as part of that process.

** Alodine 1600 is a product of Henkle Corporation.

Alchrome #2 Alchrome #16 LX-1104/LX-1105A. Concentration 1.5-2.0 oz/gal. 4.0 – 5.0% 1.28/0.22 oz/galB. pH 1.5 – 2.0 1.2 – 1.9 1.4 – 2.2C. Temperature 70 - 100°F 80 – 100°F 85 - 110°FD. Time 30 secs. – 3 min. 5 – 60 secs. 3 – 5 min.

A stainless steel or Koroseal lined tank is required.

3.4 Casting Impregnated per BW-108-P

If the plastic resin impregnation system is used the chromate conversion filmshall be applied after impregnation (Section 11, BW-108-P).







3.5 Maintenance of Solutions

Individual manufacturer’s procedures shall be used to prepare and maintainchemical content of the solutions.

4.0 QUALIFICATION REQUIREMENTS

4.1 Salt Fog Resistance

Tests shall be conducted in an approved salt fog box with 5% by weightsodium chloride at 95°F ± 5°F per ASTM B117. Coated specimens shouldbe dried at room temperature for 24 hours prior to testing.

4.2 Test Option 1

Treated parts shall have a salt fog resistance at least four times that ofuntreated parts.

4.3 Test Option 2

Five specimen panels of 2024-T3 aluminum 24 to 32 square inch area perside and 0.020 minimum inches thick shall be processed along withproduction parts. The panels should be subjected to the salt spray test for168 hours with the significant surface inclined 6 degrees from vertical.

4.3.1 After completion of the test, the panels should be cleaned in warmwater up to 100°F, blown dry with unheated air and examined for thefollowing criteria to pass the test.

a. Up to 5 isolated spots or pits up to 0.031 inch diameter areallowed per panel. Loss of color is permitted. Areas within 1/4inch of an edge, identification marks and holding points duringtesting are excluded.







b. The combined surface area on the exposed surface of the fivepanels shall have no more than 15 isolated spots or pits withnone larger than 0.031 inch diameter.

4.3.2 A non-etch cleaner is preferred for pre-process cleaning the 2024-T3panels to avoid pitting and intergranular attack. If an alkaline etch isused, an acid neutralization step should follow.

5.0 APPROVED MATERIALS AND SOURCES

Alodine 1600 Henkle Surface Technologies Madison Hts, MIAlchrome 2 Heatbath Corp. Indian Orchard, MAAlchrome 16 Heatbath Corp. Indian Orchard, MAAlchrome LX 1104 (liquid) Heatbath Corp. Indian Orchard, MAAlchrome LX 1105 (liquid) Heatbath Corp. Indian Orchard, MA

5.1 Alternate Specifications

The following specifications conform to BW-128-P

MIL – C 5541 EDIN 50939

6.0 VENDOR TESTS AND REPORTS

6.1 Suppliers of these processes applied to Bendix products shall initially submitthe results of corrosion tests per 4.0 or submit samples of the coatedproduct to the Bendix Engineering Laboratory for process approval.

7.0 REJECTION

Material not conforming to the above requirements, or written modificationsthereof, shall be rejected and the vendor notified.





4. Design FMEA:

• If the supplier has design responsibility, the BCVS expectation is to have a DFMEA in the AIAG compliant format submitted with the PPAP package.

• If the supplier considers their design to be of a proprietary nature, a waiver for this requirement must be obtained from the using plant quality function prior to PPAP submission and is to be included under this tab of the PPAP package.

• If the supplier does not have design responsibility, a page stating “Not Applicable” is to be included under this tab of the PPAP package.

NOTE 1: A single Design FMEA may be applied to a family of similar parts. NOTE 2: For Bulk Materials, see Appendix F. (AIAG 4 Edition)




5. Process Flow Diagrams:

• The supplier must include a process flow diagram that clearly describes the production process steps and sequences. The process flow step numbers should match up with the Process FMEA and Control Plan step numbers.

NOTE: Process flow diagrams for “families” of similar parts are acceptable if the new parts have been reviewed for commonality by the organization.




6. Process FMEA:

• The supplier must include a process FMEA that is compliant to the AIAG format.

• PFMEAs are to include ALL process steps, e.g. receiving, incoming inspection,

labeling, shipping, etc.

• All BCVS Special Characteristics must be included in the PFMEA.

• High RPN process steps should include actions to reduce them.

NOTE 1: A single Process FMEA may be applied to a process manufacturing a family of similar parts or materials if reviewed for commonality by the supplier.

NOTE 2: For Bulk Materials, see Appendix F. (AIAG 4th Edition)



Bendix Requirements Guideline 7. Control Plan: • Control plans for “families” of similar parts are acceptable if the new parts have been

reviewed for appropriate commonality. • Control plan approval by BCVS prior to PPAP package submission is NOT required. • Regardless of the form used by the supplier, all elements of AIAG APQP format must be addressed. • All BCVS Special Characteristics must be included in the control plan. Note 1: Control plans for ‘families of parts are acceptable if the new parts have been reviewed for commonality by the organization. Note 2: Control Plan approval may be required by Bendix.



Bendix Requirements Guideline 8. Measurement System Analysis Studies:

• MSA studies are to be submitted for all gages or families of gages used to measure the applicable product/process characteristic of the initial process capability study.

• Where Special Characteristic requirements apply, valid MSA’s for each

specific gage used to measure the Special Characteristics must be submitted. MSA studies for gage families are NOT acceptable. NOTE: Gage R & R acceptability criteria are defined in the Measurement Systems Analysis reference manual.




9. Dimensional Results:

• Dimensional results are to be included for each unique manufacturing cell or production line and all cavities, molds, patterns, or dies.

• It is expected to have a "ballooned" drawing included with the PPAP package. Each ballooned element of the drawing is to be numbered and correspond to the numbering sequence on the Dimensional Results form.

As an example, reference the drawing 298725 and Dimensional Results included in this document.

• Actual dimensional results are to be shown in the Supplier Measurement Results column of the Dimensional Results form. Write down the actual reading (or range) obtained (NOT "OK / Not OK").

• The OK/Not OK boxes are to be checked appropriately to indicate conformance of the measurements obtained to the Design Record requirements.

• Drawing notes are to be included on the Dimensional Results form, along with evaluation results.

• Dimensional results of sub-components are to be included in the PPAP submission package (see element # 1, "Design Records of Saleable Product").

• Embedded dimensional requirements within BW specifications are to be recorded.

As an example, reference the Bendix spec, BW-111-ES for flash, ejector pins, surface finish, etc. requirements included in this document.

• The organization (supplier) shall identify one of the parts measured as the

“master sample”. (see section 15)

NOTE: The Dimensional Results form in Appendix C (PPAP 4th Edition) shall be utilized for this purpose.

s

Production Part ApprovalNOTE: TO BE USED AS AN EXAMPLE ONLY. Dimensional Test Results Page _1_of __2__DOES NOT CONTAIN ALL INSP. ITEMS.

ORGANIZATION: SUPPLIER: Acme PART NUMBER: NUMBER: 298725SUPPLIER / VENDOR CODE: CODE: 909152 PART NAME: NAME: Crankcase CoverINSPECTION FACILITY Acme DESIGN RECORD CHANGE LEVEL: ECL: Rev. 7

ENGINEERING CHANGE DOCUMENTS: ECN 69978

ITEM DIMENSION / SPECIFICATION SPECIFICATION / LIMITS TEST DATE QTY.

TESTEDORGANIZATION MEASUREMENT RESULTS

(DATA) OK NOT OK

1 5.64 unspecified tolerance 5.63 - 5.65 8/12/2002 5 5.633 Unspecified tol = .010 for 2 d.p. Xper ECN. See Engineering Change Records, section 2.0

2 Dim "F" N/A N/A N/A N/A for this part number X3-1 Dia. .346 +/- .007 .339 - .353 8/12/2002 5 .349 - .352 X4-1 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .035 X

See CMM Report attached5-1 Position = .015 M, A 8/12/2002 5 True Position = .020 X

See CMM Report attached3-2 Diameter .346 +/- .007 .339 - .353 8/12/2002 5 .348 - .350 X4-2 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .026 X

See CMM Report attached5-2 Position = .015 M, A 8/12/2002 5 True Position = .020 X

See CMM Report attached

5-6 Position = .015 M, A 8/12/2002 5 True Position = .018 XSee CMM Report attached

6 Note 4 - .030 min depth from N/A N/A N/A Z dim for CMM probe set at 1/2 mat'l Xside opp. gasket surface thickness (.1121) from datum "A" for(datum "A") all hole measurements.

7 .44 Radius - unspecified tol. .43 - .45 8/12/2002 5 .443 - .446 R. Unspecified tolerance = X.010 for 2 d.p. per ECN. See Eng.Change Records, section 2.0.

8 Dim "G" = ------- N/A N/A N/A N/A for this part number X9 .50 Flatness Area N/A N/A N/A Dimension used for layout purposes X

only to define flatness area zone. 10 Note 1 - smooth within 32 32 - 125 8/12/2002 5 Ra 88 - 110 X

Microinch to 125 microinch arolled. Surface side only.

11 .009 Max flatness between .000 - .009 Max. 8/12/2002 5 Hole 1 to Hole 2 = .006 max Xadjacent holes around part. Hole 2 to Hole 3 = .008 max. X

Hole 3 to Hole 4 = .008 max. XHole 4 to Hole 5 = .005 Max. XHole 5 to Hole 6 = .007 max. X

Production Part ApprovalNOTE: TO BE USED AS AN EXAMPLE ONLY. Dimensional Test Results Page _2_of __2__DOES NOT CONTAIN ALL INSP. ITEMS.

ORGANIZATION: SUPPLIER: Acme PART NUMBER: NUMBER: 298725SUPPLIER / VENDOR CODE: CODE: 909152 PART NAME: NAME: Crankcase CoverINSPECTION FACILITY Acme DESIGN RECORD CHANGE LEVEL: ECL: Rev. 7

ENGINEERING CHANGE DOCUMENTS: ECN 69978

ITEM DIMENSION / SPECIFICATION SPECIFICATION / LIMITS TEST DATE QTY.

TESTEDORGANIZATION MEASUREMENT RESULTS

(DATA) OK NOT OK

18 3.44 - Unspecified Tolerance 3.43 - 3.45 8/12/2002 5 3.432 - 3.441 Unspecified tolerance = X.010 for 2 d.p. per ECN. See Eng. change records, Section 2.0.

22 Remove all Burrs and Sharp 0.00 Max. 8/12/2002 5 All burrs and sharp edges broken. XEdges Allowable

25 Treatment - Rust prevent per Spec. 8/12/2002 5 Rust Ban 392 used. Material is listed XSpec BW-104-P on Bendix BW-104-P spec.

Blanket statements of conformance are unacceptable for any test results.

March SIGNATURE TITLE DATE

2006 CFG-1003

BCVS ENGINEERING STANDARD BW-111-ES

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SUPERSEDES :

X

12 70310 06-12-02 Bendix Commercial Vehicle Systems LLCElyria, OH 44036

Written

JMK

Date

06-12-02

REV. ECN NO. DATEDIE CASTING POROSITY

STANDARD

APPROVED

RJC

Date

06-12-02PRODENGR FORM 004.DOC REVISED 2000/10/17

NOTICE

Bendix Commercial Vehicle Systems LLC claims proprietary rights to theinformation contained herein. This document is furnished in confidence withthe express understanding that neither it nor any copy thereof shall be disclosedto others nor used for the purpose of manufacture or procurement of the articledocumented herein, without written permission from Bendix.

© 2002 Bendix Commercial Vehicle Systems LLC, All Rights Reserved.



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1.0 SCOPE:This Standard establishes the Bendix Commercial Vehicle Systems L.L.C. (BCVS)acceptance limit for aluminum and zinc die castings and is a supplement to theindividual casting drawing. All requirements herein must be met, in addition to allother requirements of the applicable drawing.

If there is a conflict between BW-111-ES and the drawing, the drawing shall prevail.

2.0 PURPOSE:The purpose of this document is to define the BCVS acceptance level of die castingsintended for production use and to serve as an aid to the casting suppliers.

3.0 REFERENCED DOCUMENTS:

3.1 North American Die Casting Association, NADCA Product SpecificationStandards.

3.2 BW-107-ES Date Code Requirements.

4.0 GENERAL:

4.1 In those cases where a special flatness is required, it will be specified on thedrawing. Otherwise NADCA Standards shall prevail.

4.2 Mastering surfaces will be specified on the casting drawing when required.These are cast surfaces, which are used to locate the casting in a machiningfixture for first machining operations.

4.3 Die casters who intend to machine castings to obtain the specified as castdimensions must note this fact on their quotation sheet.

4.4 Key surfaces to be machined will be identified per Section 6.4 on both thecasting and machining drawings1. These machining drawings must be providedto the die caster by SBM as part of the quotation process.

4.5 Unless otherwise noted on the drawing, measurements for concentricity,perpendicularity, runout, length, etc. shall not include parting lines, gate marksor flash.

1 This is provided as an aid to the die caster in understanding BCVS casting requirements, even though thecasting supplier may not be doing the machining



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5.0 POROSITY:Die castings are never entirely free of porosity. However, this standard will attempt todefine the degree of porosity and imperfections permitted based on the functional needof both the “as cast” and “as machined” part as it pertains to their use in the BCVSorganization.

5.1 Definitions:

5.1.1 Porosity: Irregular shaped voids in the die cast part as a result of gasbubbles, impurities, shrinkage, movement of base material, etc.

5.1.2 Pore Size: The size of the porosity is defined as the largest dimensionof the pore; i.e. major diameter of a spherical or irregular shaped void,or the longest dimensions of a crack-like void. Typical descriptionsare “pin-point” which are pores .020” (0.5mm) diameter or smaller,and “pit type” which are pores larger than .020” (0.5mm) diameter.

5.1.3 Surface Porosity: Surface porosity is defined as any void occurring ata surface, either cast or machined.

5.1.4 Chain Porosity: Chain porosity is a set of interconnected poresforming a chain-like void.

6.0 REQUIREMENTS:

6.1 Working Pressure: Castings used in pneumatic control valves are designed for aworking pressure of 150 psi and must withstand a proof test2 of 600 psi withoutfailure. BCVS reserves the right to test components on production line orlaboratory equipment using either finished components or assemblies.

6.2 Leakage: The casting must be free of porosity, which may cause externalleakage.

BCVS reserves the right to test components on production line or laboratoryequipment using either finished components or assemblies.

Leakage determined to stem from air passage through gates, parting lines,casting skin or other areas created by the casting process3 will be grounds forrejection.

2 Frequency of proof testing is determined by statistical process control. Consult BCVS quality or 6 sigmadepartments for further details.3 Casting Process is further defined as the three processes of casting, annealing and cool down used in thecreation of the part. Optimized gating, reduced air entrapment, fewer cold shuts, reduced porosity andoptimized shot profiles are some of the parameters that can be optimized through the use of computersimulation. Source: www/magmasoft.com or equal.



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6.3 Porosity Levels: The level of porosity permitted will be determined by BCVSand more than one level may be specified on a part. The level of porosity forunspecified areas will be covered by a note on the casting and machiningdrawings.

6.4 Machined Surfaces:

6.4.1 Key machined surfaces will be designated on the casting andmachining drawings by using the symbol K-1 or K-2. These surfacesmust meet porosity LEVEL 1 or porosity LEVEL 2 requirementsrespectively to a depth, which will allow machining to the finisheddimension. For interpretation of these porosity levels refer toManufacturing Acceptance Standard Engineering Die CastSpecification BW-111-ES Supplement.

K-1: Machined surfaces shall not have pores larger than those in Level1 or a frequency of pore occurrence greater than that of Level 1.

K-2: Machined Surfaces shall not have pores larger than those inLevel 2 or a frequency of pore occurrence greater than that of Level 2.

6.4.2 Porosity Greater in Excess Level 3: In some instances porosity inexcess of Level 3 will be exposed in a non-critical machined zone of acasting. When it is determined by BCVS engineering that strength andgas tightness are not compromised for the section in question, porosityin excess of Level 3 will be acceptable. In addition, the porosityrequirement does not apply to those cross sectional areas of solidmaterial that are 1/8” or greater from all adjacent surfaces; forexample, material that could be cored away, if practical. Suchexceptions should be noted in an NCM and added to the drawing ifdeemed appropriate by BCVS engineering.

6.5 Surface Condition as Cast:“As Cast” sealing surfaces will be identified on the casting drawing by thesymbol S. No parting lines or die drag marks will be permitted on thesesurfaces. The surface finish, whether as a result of surface porosity, diechecking or abrasive (blast) cleaning, shall not exceed 160 microinches.

Unless otherwise specified on the casting drawing, the condition of all castsurfaces must meet North American Die Casting Association Standard NADCAG-6-6-94 Class 1. Identifying marks on castings must be completely legiblefollowing cleaning and deburring procedures. If questions occur as to legibility,they should be directed to BCVS engineering or quality department.



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6.6 Flash4 Control:Unless otherwise specified, the following requirements must be met:

6.6.1 Parting Line/External Profile Flash must be within 0.4 mm (.015”) ofthe die casting surface (Ref: NADCA G-6-5-94).

6.6.2 Cored Hole and Insert Flash must be within 0.25 mm (.010”) of the diecast surface (Ref: NADCA G-6-5-94).

6.6.3 Ejector Pin Flash must not exceed 0.60 mm (0.025”) height.

6.6.4 Removal of Flash at the Bottom of a Cored Hole: A 0.8 mm (.030”)breakout around a trimmed hole is permitted.

6.6.5 Flash from Gates and Overflows: Thick gates and overflows; trimflash must be 1.6 mm (0.060”). Thin gates; flash must be 0.8 mm(.030”). Exceptions to this must be by approval between BCVS andthe supplier (Ref: NADCA G-6-5-94).

6.7 Ejector Pins:

6.7.1 The location and size of ejector pins will be mutually agreed upon byBCVS engineering and the supplier.

6.7.2 Ejector pin marks may be raised or depressed 0.4 mm maximum(.015”) (Ref: NADCA G-6-4-94).

6.8 Cracks:Cracks which result from die trimming, part ejection, shrinkage, etc will not beaccepted.

6.9 Burrs and Sharp Edges:Burrs and sharp edges created by machining process will be removed prior toproduction use of the part, leaving a 0.08/0.38 mm (.003”/.015” break onaffected edge.

6.10 Date Codes:Casting date code will comply with BW-107-ES.

4 Flash is defined as any excess cast metal the fills the voids created from improper die closure or die cavityprofile. It represents extra cost in the form of lost die casting pressure, extra metal, increased machining scrapand potential operator harm among others. “ If you cannot take the time to correct the issue, then you cannotafford to run the die” re: www/drdiecast.com



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Bendix Requirements Guideline 10. Material, Performance Test Results

• Actual results of testing are to be documented including metallurgical, chemical, and physical testing and included in the PPAP package.

• The supplier’s material sub-contractor, testing date, and test lab used are to be included on the test results sheet.

• Note that prior BCVS Engineering approval is required for some BW specs.

As an example, reference the Bendix spec, BW-104-P included in this document.

Material Test Results shall indicate and include: • Design Record change level of the parts tested. • Any authorized engineering change documents that have not yet been

incorporated in the design record. • The number, date, and change level of the specifications to which the part was

tested; • The date on which the testing took place; • The quantity tested; • The actual results; • The material supplier’s name and, when required by Bendix, the assigned

supplier/vendor code.

NOTE: Material Test Results shall be presented as in Appendix D (PPAP 4th Edition)

Performance Test Results must also include all of the above information. Test results shall be presented as shown in Appendix E (PPAP 4th Edition)

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11. Initial Process Study:

• Initial process studies are required where Bendix Special Characteristics are applicable. See Bendix procedures QR-0010 and DPP 6.2.2.2 in this section.

• The intent is for the supplier to show that they are producing product utilizing process control. In addition to any BCVS Special Characteristics, supplier should demonstrate process control by using any other product or process characteristic that the supplier deems to be appropriate.

• The supplier shall perform measurement system analysis (see section 8) in order to understand how measurement error affects the study measurements.

NOTE 1: Bendix reserves the right to require demonstration of initial process capability requirements on any/all characteristics. NOTE 2: Attribute data are NOT acceptable for PPAP submissions unless approved by an authorized Bendix representative. NOTE 3: Bendix requirements for Cpk and/or Ppk are outlined in Bendix procedure QR-0010 and DPP 6.2.2.2. See AIAG (2nd Edition) reference manual for SPC applications. NOTE 4: Initial Process Studies (even for short term) are to be conducted using process control charts in order to collect and analyze the data. NOTE 5: Short term studies should be based on a minimum of 25 subgroups containing at least 100 readings from consecutive parts of the production run. Other analytical analysis must have prior approval from an authorized Bendix representative.

• Bendix acceptance criteria for initial studies is outlined in QR-0010 and DPP 6.2.2.2

• The supplier shall notify Bendix representatives of any unstable process that exists and submit a corrective action plan PRIOR to any PPAP submission.

• Acceptance criteria for processes with one-sided specifications or non-normal distributions need to be approved by an authorized Bendix representative.

• IF acceptance criteria can NOT be met by PPAP submission date, a corrective action plan and modified Control Plan providing for 100% inspection shall be submitted to the authorized Bendix representative. See Bendix Requirements in QR0010 sections 4.2 and 4.3.

Bendix Commercial Vehicle Systems LLC Elyria, Ohio PROCEDURE TITLE: DEPARTMENT: Quality Assurance Bendix Special Characteristics PROCEDURE: QR-0010 REVISION: 16 ISSUE DATE: January 9, 2009 PAGE: 1 of 4

Cover Sheet DISTRIBUTION: Acuña/Del Rio - Quality Manager (Hard Copy) Bowling Green - Quality Manager (Hard Copy) Huntington - Quality Manager (Hard Copy) Engineering - Leadership Team (L.A.N. Copy) Supply Base - Director (L.A.N. Copy) SQD - Manager (L.A.N Copy)

Revision History Table

REVISION # Org. 13 14 15 16

WRITTEN BY H. Bruewer J. Sims J. Sims J. Sims E. Smith

APPROVED BY H. Bruewer R. Dominguez

R. Dominguez M. Goetz M Goetz

ISSUE DATE October 27, 1988 11/15/2006 9/5/07 7/9/08 1/9/09

APPROVAL SIGNATURE

Approve UPDATED ISO QR 0010.msg

Approve QR-0010Bendix Special Chara

Please note: Revised text is in italics and also underlined Revision 16:

Distribution section removed Frankfort and replaced with Bowling Green.

Added Table of Contents to page 2

Added DPP 6.2.2.2 – Identification and Treatment of Special Characteristics as a specific reference for this procedure.

This copy was printed on 1/7/2009. Warning: The user must verify it is the current revision prior to use.

Bendix Commercial Vehicle Systems LLC Elyria, Ohio PROCEDURE TITLE: DEPARTMENT: Quality Assurance Bendix Special Characteristics PROCEDURE: QR-0010 REVISION: 16 ISSUE DATE: January 9, 2009 PAGE: 2 of 4 The information contained in this document is the property of Bendix Commercial Vehicle Systems. Table of Contents: 1.0 Previous Special (Classified) Characteristics 2.0 Restrictions 2.1 Fan Drive Exception 3.0 Concessions for Non-Conforming Material (NCM) 3.1 No concessions for Star, Shield, Diamond 3.2 Concessions for Circle c/c characteristics 4.0 Control 4.1 Short-term capability 4.2 Non-Conformance to capability requirements 4.3 Written Plan for improving capability 4.4 Control method as detailed in Control Plan for Special Characteristics (See DPP 6.2.2.2) 4.5 Capability requirements for Circle c/c Characteristics 5.0 Original Definitions – Shield, Star, Delta


Bendix Commercial Vehicle Systems LLC Elyria, Ohio PROCEDURE TITLE: DEPARTMENT: Quality Assurance Bendix Special Characteristics PROCEDURE: QR-0010 REVISION: 16 ISSUE DATE: January 9, 2009 PAGE: 3 of 4 1.0 Previous Special (Classified) Characteristics

This document obsoletes the Star, Shield, and Delta Classified Characteristics. These characteristics are still valid for existing drawings, but they cannot be used on new or revised drawings after release of this document. These characteristics must be replaced with the new S/C or C/C symbol when a drawing is updated. The circle c/c (obsolete from a previous revision) must either be updated to a new symbol or removed.

2.0 Restrictions

2.1 Fan Drive Exception: This procedure is not applicable for Fan Drive components / assemblies and assembly processes. Special (Classified) Characteristics assigned to the fan drive drawings were based on other criteria, not driven by DFMEA. Therefore, the Special Characteristics assigned to fan drive component / assemblies and processes are not valid nor covered by this document.

3.0 Concessions for Non-Conforming Material (NCM)

3.1 No concessions are allowed for Star, Shield, and Delta symbols.

3.2 Concessions are allowed for circle c/c only with signed approval from the Product Engineer and the Customer (if applicable).

4.0 Control

4.1 All Star, Shield, and Delta symbols are to be produced on a process with a minimum short-term capability of 1.67 Cpk (±6 Sigma). The long-term capability of the process must be monitored and maintain a 1.33 Ppk minimum.

4.2 All characteristics not meeting capability requirements must be checked 100% on a device (test stand or inspection equipment) that is free from operator interpretation.

4.3 Any Special Characteristic that does not meet capability must have a written plan for improved capability established and approved by the Plant Quality Manager.

4.4 The control method must be detailed in the control plan for all Special Characteristics. Specific controls are detailed in Procedure DPP 6.2.2.2. The required sample size will follow the latest edition of AIAG PPAP manual or as agreed upon in the control plan.

4.5 Circle c/c characteristics still on drawings must have an initial short term capability Cpk of 1.33. It is not necessary to track long term capability.

5.0 Original Definitions

Shield: This characteristic is typically associated with requirements under applicable regulation or legislation.

Star: This characteristic is typically associated with a Severity Rating of 9 or 10

n the Design FMEA. Assigning a star characteristic to the drawing requires prior approval of the Product Integrity Committee (PIC).


http://a2wls.grp.knorr-bremse.com:8080/weblink_servlet/weblink?DocumentName='QS9000-PPAP'&Class='k3StdDoc'&k3Language='EN'&LifeCycleState='LcsReleased'&CurDbName='archive'

Bendix Commercial Vehicle Systems LLC Elyria, Ohio PROCEDURE TITLE: DEPARTMENT: Quality Assurance Bendix Special Characteristics PROCEDURE: QR-0010 REVISION: 16 ISSUE DATE: January 9, 2009 PAGE: 4 of 4

▲ Delta: This characteristic is typically associated with a Severity Rating of 8 in the Design FMEA.





12. Qualified Laboratory Documentation:

• The supplier shall have Inspection and Testing for PPAP (as well as regular production) performed by a qualified laboratory as defined by customer requirements. (e.g. an accredited laboratory)

• The supplier’s qualified laboratory (internal or external) shall have a laboratory

scope and documentation showing that the laboratory is qualified for the type of measurements or tests being conducted.

• Supplier shall submit test results on the laboratory letterhead or the normal

laboratory report format when an outside laboratory is used. The following information must be included on the report: • Name of the laboratory that performed the tests. • The date(s) of the tests. • The standard(s) used to run the tests shall be identified.




13. Appearance Approval Report:

• The AIAG format is to be used. • A separate AAR must be completed for each Bendix part number unless

otherwise agreed to by the part approval activity of the using facility. • An AAR is required for each part for which a submission is required if the

product/part has appearance requirements on the design record. When in doubt, contact the using plant quality function.

NOTE 1: AAR typically applies only for parts with color, grain, or surface appearance requirements. NOTE 2: Certain customers may not require entries in all AAR fields. See Appendix B (PPAP 4th Edition) or customer-specifics for detailed instructions on completing the AAR.



Bendix Requirements Guideline 14. Sample Product:

• Unless otherwise specified by the using plant approval activity, the supplier shall submit 3 samples with the PPAP. If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process, e.g. line or cell, then the supplier shall submit one sample for each position of a multiple cavity die, mold, tool or pattern, or production process. Such samples shall be appropriately identified.




15. Master Sample:

• Unless otherwise specified by the using plant approval activity, the supplier shall retain master samples per AIAG PPAP requirement. See AIAG (PPAP 4th Edition) section 2.2.15 on Master Sample retention.

• If production parts will be produced from more than one cavity, mold, tool, die,

pattern, or production process, e.g. line or cell, then the supplier shall retain one sample for each position of a multiple cavity die, mold, tool or pattern, or production process.



Bendix Requirements Guideline 16. Checking Aids:

• It is a recommended best practice for the supplier to submit digital pictures of checking aids such as fixtures, models, gages, templates, mylars etc. Pictures should show the checking aid itself, and how it is used with the part being evaluated.

• If required by Bendix, supplier shall submit with the PPAP submission any part-

specific assembly, component checking aid, or the design/purchase source of same.

• Supplier shall certify that all aspects of the checking aid agree with part

dimensional requirements.

• Supplier shall provide for preventive maintenance/calibration of any checking aids in their possession for the life of the part.

• Measurement systems analysis studies shall be conducted in compliance with

Bendix requirements. (See MSA AIAG manual – 3rd Edition)



Bendix Requirements Guideline 17. Records of Compliance With Customer Specific Requirements - BCVS Specific: • Conformance to QR0010, BCVS Special Characteristics. Reference QR-0010 and DPP 6.2.2.2 at element # 11, "Initial Process Study". • Labeling requirements Ref BW-5348, and packaging requirements, Ref BW-5347. Reference the Bendix procedures BW-5348 and BW-5347 included in the BCVS Business Manual. • Supplier should submit samples of labels, and pictures or sketches of packaging. • The supplier shall have records of compliance to all applicable Bendix-specific requirements.



Bendix Requirements Guideline 18. Part Submission Warrant:

• The AIAG Part Submission Warrant (North American Truck Industry or Automotive) must be used. See AIAG/PPAP Manual – 4th Edition.

• All fields listed on PSW must be addressed. Information must be inserted in each

cell.

• A separate PSW must be completed for each Bendix part number unless otherwise agreed to by the part approval activity of the using facility.

• Unless otherwise specified by the Bendix using facility, use the instructions in the

AIAG PPAP Manual – 4th Edition, for filling out the Part Submission Warrant.


Production Part Approval Process (PPAP) Bendix Requirements Guideline 19. Supplier Change Notification and Submission Requirements:

• Suppliers shall notify the authorized Bendix representative (via [email protected]) of any planned changes to the Product Design, Process, or Site of manufacture.

• See Table in AIAG PPAP Manual – 4th Edition, for examples of changes requiring

notification and approval by Bendix.

• IF Change Notification is required, Supplier shall use the PRODUCT/PROCESS CHANGE NOTIFICATION FORM in the Bendix Supplier Business Manual or on the Bendix Internet Site at www.Bendix.com. Complete form as per instructions.

• Submit PPCN form to your authorized Bendix representative BEFORE

SUBMITTING PPAP TO THE USING PLANT . Wait for Bendix approval BEFORE proceeding with the requested change.

• PPAP Submission is required unless otherwise specified.


PPAP ACRONYMS FOR BENDIX PPAP MANUAL – 1ST REVISION

AAR – Appearance Approval Report

AIAG – Automotive Industry Action Group

APQP – Advanced Product Quality Planning

ASTM – American Society for Testing Materials

BCVS – Bendix Commercial Vehicle Systems

BW – 11 1 – ES Bendix Westinghouse – 111 – Engineering Standard

C/C – Critical Characteristic

CMM – Coordinate Measuring Machine

Cpk – Long Term Capability

DFMEA – Design Failure Mode and Effects Analysis

DPP 6.2.2.2 – Detail Process Procedure 6.2.2.2

ECL – Engineering Change Level

ECN – Engineering Change Notice

FMEA – Failure Modes and Effects Analysis

Gage R & R – Gage Repeatability and Reproducibility

ISO – International Standards Organization

LLC – Limited Liability Company

MCR – Material Concession Request

MSA – Measurement Systems Analysis

NCM – Non Conforming Material

PPAP – Production Part Approval Process

PpK – Short Term Capability

PSW – Part Submission Warrant

QR – 0010 - Quality Requirement 0010

RPN – Risk Priority Number

S/C – Significant Characteristic

SBM – Supply Base Management