5 - supplier handbook for prototypes - body

7/23/2019 5 - Supplier Handbook for Prototypes - Body

http://slidepdf.com/reader/full/5-supplier-handbook-for-prototypes-body 1/29

Supplier Handbook for prototypes

Module: Body

Responsible: Marco Bührig, GQE-V/P

Status: ReleasedVersion: February 2015

Date: 01/02/2015



The English translation is believed to be accurate.In case of discrepancies, the German version is alone authoritative and controlling.

Supplier Handbook for prototypesModule: Body 2

Table of contents

1. Requirements............................................................................... 3

1.1

Documentation .............................................................................................. 3 1.2 Inspection equipment suitability ..................................................................... 5

1.3 Quality requirements for drawn and body components ................................. 5

1.4 Assessment of producibility (deep-drawing simulation) ................................. 6

2. Inspection and evaluation ............................................................ 6 2.1 Requirements for individual parts .................................................................. 6

2.2 Requirements for assemblies ........................................................................ 6

2.3 Measurement programs ................................................................................ 7

2.4 E-ZP5 acceptances ....................................................................................... 8

2.5 E-ZP5A acceptances ..................................................................................... 9

2.6 Measurement fixtures .................................................................................... 9

2.7

Material thinning .......................................................................................... 10

2.8 Dimensional accuracy index (MI) ................................................................ 11

2.9 MI evaluation for target tracking and target parameters for assemblies ...... 13

3. Inspection reports ........................................................................................ 14

3.1 Inspection report cover sheet ...................................................................... 14

3.2 Graphical depiction of the orientation in accordance with RPS ................... 15

3.3 Graphical depiction of the target data and deviations .................................. 16

4. Assembly (ZSB) ......................................................................... 23 4.1 Inspection of joints ....................................................................................... 23

5. Hot-formed parts ........................................................................ 24

5.1

Inspection of hot-formed parts ..................................................................... 24 5.2 Material specimens...................................................................................... 25

5.3 Parts marking .............................................................................................. 25

5.4 Processes and materials ............................................................................. 26

5.5 Production ................................................................................................... 26





1. Requirements The contractor shall designate a Q contact partner for the quality assurance department (Q)

of the contractee. This Q contact partner shall establish contact with the quality assurancedepartment of the contractee in order to agree the Q requirements.

1.1 Documentation

The basic responsibility for documentation lies with the party that creates an individual part or

constructs an assembly or makes changes thereto (contractor). Documentation and

inspection requirements will be agreed between the contractee and contractor.

Evaluations for the assembly main groups: It is fundamentally necessary to produce

individual evaluations (measurement result for one unit) and collective evaluations

(measurement results for 5 units or more).

Individual evaluations comprise the following:

- target value, actual value, tolerance, deviation

Collective evaluations comprise the following:

- target value, deviations (5 units or more)

Furthermore, red range evaluations (see figure 3) shall be performed, followed up, and made

available in updated form to the contractee at defined time intervals (for example weekly),

over the entire period.

Red range lists comprise the following:

- All measurement points of one assembly, and the deviations thereof, shall be

presented in accordance with the construction sequence.

- To visualize the dimensional accuracy, the deviations of the inspected featuresshall be provided with a coloured background (green/yellow/red). Regarding

gradation, see dimensional accuracy index.





Individual evaluation example

Fig. 1

Multiple evaluation example (5 off)

Fig. 2





Red range list example

Fig. 3 (for colour key, see page 12)

1.2 Inspection equipment suitability

The following limit values must be adhered to:

for single-stand measurement installations: MPEE = 30 µm + L/40 µm 100 µm, and

for double-stand measurement installations MPEED = 40 µm + L/40 µm 120 µm

The supplier bears responsibility for documenting these processes.

1.3 Quality requirements for drawn and body components

For drawn and body components, the following requirements, among others, must be

complied with:

- test parts conforming to drawings

- absence of cracks

- no inadmissible welds

- no bulging at spot and connection surfaces – no drawing and crimping folds

- no material displacement and overlap

- no inadmissible material weakening at the radii or transitions

- no inadmissible material reduction





- no inadmissible heat treatment

- delivery in a corrosion-free state

- deburred

- With regard to subsequent painting, the component surface shall have no visible

- and perceptible (tangible) flaws- For crash-relevant components (which will be designated in the contract by the

responsible contact partner [see general part, section 1.5]), material tests shall be

carried out. A target/actual comparison shall be established, with a statement

regarding compliance with requirements.

1.4 Assessment of producibility (deep-drawing simulation)

Further to the specifications in the Supplier Handbook for prototype parts (General part), this

part goes into greater detail as regards how the assessment of producibility should be

performed for particular metal panel parts. Here, the most definitive method is the deep-drawing simulation. The deep-drawing simulation shall be performed for certain parts (which

will be designated in the contract by the responsible contact partner [see general part,

section 1.5]) in accordance with VW standard 01170: 2007-02, and results which infer

restricted producibility or non-producibility shall be made available, at no cost, to the quality

assurance department of the respective prototyping/pre-series centre. The same applies to

parts which are not included in the list but which likewise exhibit only limited producibility or

non-producibility. Limited producibility or non-producibility is to be understood as: crack

formation, fold formation and/or bulge formation within the part based on the simulation.

2. Inspection and evaluation 2.1 Requirements for individual parts

Unless agreed otherwise with the respective quality assurance department of the

prototyping/pre-series centre, the supplier is solely responsible for defining the features

inspected and the inspection scope in accordance with the manufacturing method in order to

ensure their supply quality. The measurements, inspections and qualitative evaluations of

prototype parts shall fundamentally be performed in accordance with the drawing

documentation approved by the responsible contact partner (see general part, section 1.5)and/or in accordance with the applicable data set. The components to be measured and the

inspection intensity will be designated by the above-mentioned contact partner, and shall be

documented by way of inspection reports.

2.2 Requirements for assemblies

For statements regarding manufacturing quality and testability, measurements must be

performed for an assembly; it is the sole responsibility of the contractor to perform said

measurements. In the event of significant deviation outside tolerances, suitable reworking

measures shall be implemented in agreement with the contractee.





The measurement requirements and the tolerances shall be agreed with the contractee. If

appropriate, inspection requirements applicable in the case of assembly main groups, such

as for example inspection feature plan (PMP) and functional dimension catalogue (FMK),

which are then provided by the contractee, shall be taken into consideration. The initial

measurement must fundamentally be completed and documented before any reworking. Inthe event of any reworking, a further measurement (final measurement) shall be performed.

In the case of assembly subgroups (which do not have a PMP from the contractee), the

contractor bears sole responsibility for defining the inspected features (see B - General Q

part, section 3.3). The contractee reserves the right, if necessary, to agree with the

contractor which features shall be subjected to inspection and measurement. The contractor

bears sole responsibility for the measurements, any measurement programs, documentation

and any manufacturing-monitoring activities.

Repeatability of the measurements must be ensured in all situations. The measurementreport must document the release status of the assembly.

Inspection intensity for assembly main groups

The inspection intensity for the assembly main groups can be found in the brand-specific parts!

Inspection intensity for assembly subgroups

From a price aspect, it is basically the case that one measurement report per subassembly is

expedient. The contractee will define the final inspection intensity.

It is basically the case that, if multiple measurements are necessary per subgroup in order to

achieve the quality aims, the costs of additionally required measurements shall be borne by

the contractor. The contractee shall bear the costs for only one measurement. Basically, the

first assembly shall be documented by way of one measurement report. To achieve process

reliability at an early stage, measurements shall be performed with increased regularity in the

initial construction phase. The assemblies to be measured will be defined by way of the

vehicle list/construction sequence.

A reduction in inspection intensity may be implemented only after prior agreement with the

contractee.

2.3 Measurement programs

For the assembly main groups of box-type bodyshell, UB2 (platform), attachment parts

(doors, lids, flaps), interior and exterior side parts, inspection requirements (PMP and FMK)

are provided by the contractee. In accordance with these inspection requirements, the

contractor shall provide CNC measurement programs (in DMIS format), taking into

consideration the measurement point names, the measurement principles (VW standard

101 15) and the RPS orientations (VW standard 010 55), at the latest three days before initial

measurement.

Upon the initial measurement, the measurement programme will be run-in (debugging, fault

elimination). The measurement programme will be accepted by the contractee afterdiscussion of the measurement report produced and plausibility checking. The contractor

shall notify the contractee of the appointment for the first measurement, for joint acceptance,





at least one week in advance, and shall finally communicate the appointment (including

details of the time) at the latest 2 days in advance. Measurement results must be exportable

in a format agreed with the contractee (for example DMIS format DMO).

Compatibility of the measurement programs between contractor and contractee must be

agreed in advance. The measurement programs and evaluation requirements (seedocumentation) will be transferred to the contractee at no cost if required.

2.4 E-ZP5 acceptances

For E-ZP5 (body before painting), for the prototypes and possibly other test vehicles (for

example development vehicles, concept vehicles, substructure...), acceptance shall be carried

out by the responsible quality control department of the contractor (with for example E-ZP5

checklist, signature card, weight card, E-ZP5 acceptance report). The required acceptance

appointment shall be notified to the contractee and test vehicle customer one week in advance,

and finally communicated (including details of the time) at the latest 2 days in advance.This encompasses the visual and dimensional assessment of the joints (joint dimension and

flushness) and a dimensional inspection of the sealing and roof channel dimensions in

relation to the technical specifications. Furthermore, the weight measurement of the body

and of the body assemblies shall be agreed with the contractee, performed and documented

in the weight card.

Said documents are documented on a vehicle-specific basis by the quality assurance

department of the contractor for the Volkswagen brand in the EASy4Q system (electronic

vehicle identity card). In the event of deviations and objections arising from the inspection,

the contractor is responsible for bearing the costs of any reworking. Defects that arise or are

identified for the first time during the course of the vehicle acceptance run or during

subsequent use shall likewise be rectified at the cost of the contractor (if no subsequent

design changes have been made by the contractee).

Only for so-called special vehicles with special demands on appearance and impression

such as

- Overall release vehicles (GFF)

- Exhibition and press vehicles

- Board of Management vehicles

shall an E-ZP5 audit (bodyshell audit) be performed by a certified auditor (conforming to

Group standard) in agreement with the quality assurance department of the contractee.

For a qualitative assessment, in the case of special vehicles, the following installation parts,

for example, must be installed (if the deadline allows) for E-ZP5 acceptance:

- Bumpers

- KU assembly carrier

- Fuel filler flap module

- Headlights

- Tail light cluster- Door seals

- Lock parts for flaps and doors





- Panoramic sliding roof/panoramic tilting roof

- Roof railing

- Windows

- Outer panels of the A/B/C pillars

2.5 E-ZP5A acceptances

For so-called special vehicles with special demands on appearance and impression such as

- Overall release vehicles

- Exhibition and press vehicles

- Board of Management vehicles or special vehicles

shall an E-ZP5A audit (paintwork surface audit) be performed by a certified auditor

(conforming to Group standard) in agreement with the quality assurance department of thecontractee.

For the first three bodies of a new construction stage/integration stage and for all special

vehicles, endurance running vehicles, acoustics vehicles and corrosion vehicles, a

corrosion/functional inspection, or an audit (acoustic bulkhead, fine and coarse seam sealing,

deadening mats, KTL coating etc.), will be performed by the quality control department of the

contractor (with E-ZP5A checklist). The summons to the inspections shall be issued at least

one week in advance. In the event of deviations and objections arising from the inspections

and audits, the contractor is responsible for bearing the costs of any reworking. Defects that

arise or are identified for the first time during the course of the vehicle acceptance run or

during subsequent use shall likewise be rectified at the cost of the contractor (if no

subsequent design changes have been made by the contractee).

2.6 Measurement fixtures

If measurement fixtures are requested by the contractor, these shall be labelled as property

of Volkswagen AG (labelling of special production equipment for prototypes in conformance

to VW 34022).

For the assembly subgroups/UB2/box-type bodyshell and attachment parts (doors, lids,

flaps, wings), it is fundamentally the responsibility of the contractor to provide measurement

fixtures, unless the contractee makes preferred series measurement fixtures available for the

construction period. The costs of the measurement fixtures must be listed separately in the

quotation. The required assembly subgroup measurement fixtures shall be agreed with the

contractee after commissioning.

In the case of the UB2 platform and box-type bodyshell measurements, fixture columns shall

be used which allow for the degrees of freedom of the RPS specifications.

To ensure a reproducible basis for these measurements, the Z vehicle coordinates must be

kept on the RPS surfaces by way of hook clamps.





2.7 Material thinning

The admissible material thinning is dependent on the mechanical/technological

characteristics, for example expansion and forming limit, predefined by the material.

The limit values can be found in DIN EN 10143, DIN EN 10131, VW 01070 and VW 01170.

Material thickness inspection is included in the test report. The greatest reduction of material

thickness in % must be stated under point C on the cover sheet of the inspection report.

Those regions which are subjected to intense load in the drawing process will be inspected.





2.8 Dimensional accuracy index (MI)

The dimensional accuracy index (MI) constitutes a summary of the measurement results.

These are graded into green, yellow and red ranges.

The result of the enumeration in the corresponding range shall be documented on the cover

sheet of the inspection reports as follows:

Example: Explanation:

Dimensional accuracy index 93% = Green range

7% = Yellow range

93% / 7% / 0% / 135 MP 0% = Red range

135 MP = Number of measurement points

Green range 0 - 75% utilization of the tolerance (OK range),

Yellow range 75 - 100% utilization of the tolerance (regulation range),

Red range <256 outside the tolerance (reworking range).

The greatest deviations shall be stated on the inspection report cover sheet (under C),

stating the measurement point number and the measurement report page. The number of

measurement points that lie outside double the tolerance shall be stated.





The gradation of the Green, Yellow, and Red ranges is dependent on the tolerance

utilization in %:

0-75% 75-100% >100%

Sollwert

symmetrisches Toleranzfeld -1 0 +1

asymmetrisches Toleranzfeld 0 +2

asymmetrisches Toleranzfeld -0,75 0 +1,25

Toleranzverhältnis

Beispiel +1,0 / -1,0 mm Toleranz

0,25 0,25

0,250,25

0,250,25





2.9 MI evaluation for target tracking and target parameters for assemblies

For the assemblies evaluated in accordance with PMP/FMK, the contractor will issue a

weekly MI evaluation, in accordance with construction sequence, for BM (report

measurements), FM (functional dimensions), and BM + FM total.

The target parameters shall be agreed with the contractee, or looked up in the brand-specificpart, for each construction stage.

The target parameter shall be depicted by means of a line as in the example.

Example (target parameter with 75%)

Maßhaltigkeit FunktionsmaßeVWxxx Kastenrohbau Abgabestand

7782 83

72

8085

7582

75

14

12 11

18

137

10

9

13

96 6

107 8

159 12

0%

10 %

20 %

30 %

40 %

50 %

60 %

70 %

80 %

90 %

100%

V W x x x

V W x x x

V W x x x

V W x x x

V W x x x

V W x x x

V W x x x

V W x x x

M i t t e l w e r t

M a ß h a l t i g k e i t s i n d e x i n

<= 75% > 75% u. <=100% > 100% Toleranzausnutzung

Ziel 75% grün + gelb

Zeitraum: Jun 2009 - Nov 200 9

08 Messungen

03.11.2009

95 FM





3. Inspection reports

3.1 Inspection report cover sheet

Firmenlogo Fi rmenname

EA-Nummer Prüfberichtsnummer

Projekt

Teilebenennung Teilenummer Zeichnungsnummer Datenstand

Zeichnungsstand Geometriestand

Blatt techn. Ansprechpartner / Auftraggeber Stück geliefert / geprüft Werkstoff Gewicht

verwendbar für:

von Nr. bis Nr. Lieferant (Lieferantennummer) Lieferschein/vom Los-Nr.

/ Prüfteil-Nr.

Generationsstand/Werkzeugtyp

Absprachestand vom: abgestimmt mit:

Name: Firma:

Abteilung: Telefon:

Qualitätsstatus: Prüfer: Verteiler:

Datum:

Unterschrift:

Telefon:

Maßhaltigkeits-Index: Geprüft:

Datum:

Unterschrift:

Telefon:

D Bemerkung E Stellungnahme

Auftraggeber

P R Ü F B E R I C H T

B Ausrichtung A Grund der

Prüfung

C Prüfergebnis

Auftrags-/Bestellnummer





3.2 Graphical depiction of the orientation in accordance with RPS





3.3 Graphical depiction of the target data and deviations





4. Assembly (ZSB)4.1 Inspection of joints

Weld spot inspection:Documentation of strength of spot-weld joints on assemblies shall be ensured, and confirmed

on the inspection report cover sheet under point "D", in accordance with standards VW

01105-1, VW 01105-2, VW 01105-4, PV 6702 and data sheet DVS 2916. Non-destructive

testing methods can be used but must be verified by destructive tests at regular intervals. A

visual inspection shall be performed for every component. To ensure process reliability, a

weld sample shall be produced, and subjected to destructive testing, for each metal panel

pairing. If required, these samples shall be made available to the respective brand of the

Volkswagen Group (Audi, SEAT, ŠKODA, Volkswagen). The procedure for projection-weld

joints is similar to that for spot-weld joints (see standard PV 6727).The first 3 units/assemblies of a new construction lot shall be inspected using ultrasound to

verify the welding process.

Crash bodies represent a special case. Every crash unit must be inspected using ultrasound.

Those weld spots of said units which are not OK must be documented by photograph,

specifying the weld spot names, and made available immediately to the contractee. Reworking

of said weld spots shall be performed only in agreement with the contractee. Further inspection

activities (for example hydropulse, endurance tests) shall be agreed with the contractee.

Inspection of laser-welded joints and laser-brazed joints:

Documentation of strength of laser-welded joints and laser-brazed connections on

assemblies shall be ensured, and confirmed on the inspection report cover sheet under point

"D", in accordance with standards VW 01141-1, VW 01143-1, PV 1602, PV 6709 and PV

6719. A visual inspection shall be performed for every component. To ensure process

reliability, a weld/braze sample shall be produced, and subjected to destructive testing, for

each welded/brazed connection.

If required, these samples shall be made available to the respective brand of the Volkswagen

Group (Audi, SEAT, ŠKODA, Volkswagen). *

Inspection of studs and weld and rivet nuts:

Documentation of strength of the connections shall be ensured, and confirmed on the

inspection report cover sheet under point "D", in accordance with standards VW 01107, VW

01103, VW 60431, VW 60435 and VW 60564. A visual inspection shall be performed for

every component. To ensure process reliability, a sample shall be produced, and subjected

to destructive testing, for each connection.



Inspection of connections produced by gas-shielded welding:

Documentation of strength of connections produced by gas-shielded welding on assembliesshall be ensured, and confirmed on the inspection report cover sheet under point "D", in

accordance with standards VW 01106-1, VW 01106-2, VW 01106-3 and PV 6728. A visual





inspection shall be performed for every component. To ensure process reliability, a weld

sample shall be produced, and subjected to destructive testing, for each weld joint.



Inspection of adhesive connections:

Documentation of strength of adhesive connections on assemblies shall, in accordance with

standards PV 2043, PV 2047 and PV 2049, be ensured and confirmed on the inspection

report cover sheet under point "D".

A visual inspection shall be performed for every component. To ensure process reliability, a

sample shall be produced, and subjected to destructive testing, for each adhesive connection.



* Assemblies for crash vehicles: for crash vehicles, connections that are not OK shall be

documented in detail with photographs, and the further procedure shall subsequently be

agreed with the contact partner (see general part, section 1.5).

The following inspection specifications shall be adhered to:

PV 6702 – Spot-weld joints

DVS 2916 – Inspection of spot-weld joints

PV 1602 – Laser-beam and plasma brazing of body assemblies

PV 6719 – 3-panel welding (laser-beam weld joints)

5. Hot-formed parts5.1 Inspection of hot-formed parts

Material thinning

The maximum permissible amount of partial material thinning is 20%, irrespective of

panel thickness.

Crash-relevant components may have a higher requirement than the 20% rule:Guideline for thermoformed and hot-formed prototype parts and project-specific specifications.

It is the responsibility of the manufacturer to ensure that the material thinning is not exceeded.

Visual inspection

All deliveries of hot-formed parts must be visually inspected for flawless quality. The

inspection shall be performed at an ergonomically dimensioned and well-illuminated

inspection station. The quality requirements for deep-drawn and body parts stated in the

Supplier Handbook for prototype parts apply.





Laboratory inspection report

See applicable documents to determine the areas from which samples must be taken from

the component for testing tensile strength, hardness and material thickness and creating

microsections.

Testing intensity shall be agreed with the responsible contact partner depending onquantities and delivery batches (see General part, section 1.5). Additional tests which are

necessary to document stable manufacturing processes shall be performed on a cost-neutral

basis, and shall be incorporated into the process documentation by way of the form.

It must be possible to assign the tests to a delivery batch, and the tests must be identified in

the same way as parts. The results of the tensile test must be presented as a stress-over-

elongation diagram. Hardness tests will be documented by the laboratory in Vickers (HV)

(see +20).

5.2 Material specimensMaterial specimens used to determine welding parameters shall be provided by the supplier

(e.g. resistance spot welding, projection welding, stud welding).

5.3 Parts marking

The marking of the components with batch/component number (1/19) must be such that the

durability and legibility is ensured over the service life of the parts (for example by stamping

or engraving). Subsequent work procedures must not affect the legibility of the marks. Every

component must be uniquely assigned to the “Process documentation of hot-formed

components” and to the test samples.

Labels must be attached to metal panel parts as follows:

- by fabric tape

- by stickers which can be removed without residue by a single pull-off action (not for

thermoformed parts)

- by detachable cable ties

It must be ensured that holes in which standard parts are still attached are not used for

fastening purposes.





5.4 Processes and materials

The supplier shall define parameters and regulation ranges relevant to the manufacturing

process and verify these by way of by capability documentation. Compliance with

parameters in prototype part production must be documented.

- Material (composition and measured thickness of blank)- Blank tolerances (according to DIN EN 10131)

- Oven temperature*

- Period that blank remains in oven

- Blank temperature after positioning on the tool*

- Tool temperature at the time of the deformation process*

- Part temperature upon removal from the tool*

- As appropriate, size and location of provisions on tool to impede possible spring-back

* Automated temperature measurement and documentation shall be sought!See annex: process documentation for hot-formed components

Compliance with the material data specified in the drawings must be verified (e.g. concerning

TL provisions or concerning banned heavy metals). Batch-related influences on product

quality, such as input materials and process-related influences, must be considered when

defining the scope of inspection.

5.5 Production

Hot-formed parts are produced by direct drawing (TL 4225).

Retroactive manual reworking of the component form (stretching or drawing-in of material,

processing by hammering etc.) is not admissible.

Approval must be obtained from the contractee in the event of deviations from the production

method. This approval must be renewed and documented in the process documentation

every time the data version (TM) is changed.

5 - supplier handbook for prototypes - body

Documents