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PRODUCTION PART APPROVAL PROCESS (PPAP)

Supplier Name/Location/Supplier Code:Bourns Electronics Ireland Mahon Industrial Estate Blackrock Cork Ireland

Customer part number

Supplier Part Number:

583 242 99Part/Family Description:

FUELCARDSubmission Date:

23/11/2005

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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PRODUCTION PART APPROVAL PROCESS (PPAP)

CONTENTSTS16949 CERTIFICATION PART SUBMISSION WARRANT DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART CONTROL PLAN / MEASUREMENT SYSTEM STUDIES PART DRAWING & DIMENSIONAL REPORT RESISTANCE MEASUREMENT REPORT MATERIAL CERTIFICATION & IMDS APPROVAL APPEARANCE REPORT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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PRODUCTION PART APPROVAL PROCESS (PPAP)

PART SUBMISSION WARRANT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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Part Submission WarrantBourns Part Number Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing Number SUPPLIER MANUFACTURING INFORMATION BOURNS ELECTRONICS Supplier Name MAHON INDUSTRIAL ESTATE Street Address BLACKROCK CORK City Note: State Zip Yes No

3714X-BFY-000Yes No

Customer Part Number

583 242 9910/17/2005N/A

Engineering Drawing Change Level NONE Purchase Order No.

C 70014346

Dated Dated

SUBMISSION INFORMATION Dimensional Materials/Function Appearance

Customer Name/Division

PRICOL

Has this part been reported in IMDS (or equivalent)?

REASON FOR SUBMISSION Initial submission Engineering Change's) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and complete supporting data submitted to customer. Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests YES appearance criteria NO statistical process package These results meet all drawing and specification requirements: DECLARATION I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements. EXPLANATION/COMMENTS: Print Name Supplier Authorized Signature Supplier E-mail Address FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition: Approved Rejected Title (If "NO" - Explanation Required) Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part Processing Parts produced at Additional Location Last PSW > 1 year old Other - please specify

QTY 100 QTY 100Sample co ordinator Phone No.00353 21 4515 381

Fax No. 00353 21 4515 292

Date

10/11/2005

Customer Name

Customer Signature

Date

uantities until functional approval or waiver is PPAP DOCUMENT NO.:0009-P ECO No.:05-0168 BOURNS ELECTRONICS IRELAND om customer.

5/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

6/29

PRODUCT PART APPROVAL PROCESS(PPAP)

Bourns Electronics (Irl) Failure Mode & Effects AnalysisItem : Automotive Fuel Level Sensor Model :3710X-XXX, 3714X-XXX Core Team : JL, MO'B, SPOS, PB, EO'R Design FMEA

FMEA Number : FMEA Revision : Prepared By : FMEA Date (Rev.) FMEA Date (Orig.) D e t e c t1 1 1 1

DFM-C0002 Rev G

ECO No.: 05-0046 S P O'Sullivan 21-Feb-05 01-Aug-96

Design Functions & Requirements

Potential Failure Mode

O C Potential Potential S c l Cause(s) / Current Design Effect(s) of e c a Mechanism(s) Controls Failure v u s of Failure r sGauge Inaccuracy Gauge Inaccuracy Gauge Inaccuracy Gauge Inaccuracy Gauge Inaccuracy No gauge reading No gauge reading Eratic opencircuit Incorrect Output 7 7 7 7 M M M M Incorrect Design Low ohms/square Incorrect Design Low ohms/square Material unsuitable for environment 4 4 4 4 PPAP sample qualification PPAP sample qualification PPAP sample qualification PPAP sample qualification

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R P N

Resistor

Too Low Too Low Too high Too high

28 28 28 28

Resistor value Drift

6

M

PPAP sample 5 qualification, customer 2 tests 5 Design Rules, PPAP, Gerber View, Artwork 1 Inspection PPAP sample qualification 2

60

Termination

Open circuit

8

C

Incorrect Design

40

Open circuit

8

C

Incorrect material selection, Premature 2 element wear

32 Include in the product template for all product that requires probing near the potential wiper Template updated, design procedure

Probe mark on resistor card. Incorrect Circuit Layout

8

Positioning of probe C points on wiper travel 4 area. C Design Errors 7

Not listed. PPAP sample qualification

5

160

John O'Connell 16-1-05 12/01/2005

8

1

5

40

7

1

49

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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PRODUCT PART APPROVAL PROCESS(PPAP)O C Potential Potential S c l Cause(s) / Current Design Effect(s) of e c a Mechanism(s) Controls Failure v u s of Failure r sErratic output 7 c Incorrect gap between tracks 7 Design Rules, PPAP, Artwork Inspection Design Rules, PPAP, Artwork Inspection

Design Functions & Requirements

Potential Failure Mode

D e t e c t1

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R P N

Termination

Shorts circuit

49

Short circuit

Erratic output

7

c

Incorrect Design

3

2

42

Resistor value drift

Erratic gauge output

7

m

Material unsuitable for environment

PPAP sample 5 qualification, customer 2 tests Drawing checked by Design Engineer, PPAP Sample Qualification

70

Reliability testing to be carried out to verify material suitability

Tom Burke 2003/4

Completed, Drift within specification.

7

4

2

56

Substrate Dimensions

Parts not to size

Incompatible with customers 8 assembly

M

Design Errors

5

1

40

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

8/29

PRODUCT PART APPROVAL PROCESS(PPAP) POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)Item Automotive Fuelcard Process Responsibility Bourns Ireland Mfg Eng Model 3714X-XXX-XXX Key Date : 22nd June 2005 Core Team M Delaney-Man, P Bradley - NPI,S.P.O'Sullivan - Qaulity,P Berry - Thickfilm Eng,EO'Regan - Prod Line Mgr C Potential Process Potential S l Cause(s) / Functions & Potential Effect(s) of e a Mechanism(s) Requiremen Failure Mode Failure v s of Failure ts sYield impact/Line down

FMEA Number : FMEA Revision : ECO No.: Prepared By : FMEA Date (Rev.) FMEA Date (Orig.)

PFM-C0003 Rev M 05-0132 S P O'Sullivan 22-Jun-05 27-May-99

O c c u r

Current Process Controls Prevention

Current Process Controls Detection

D e t e c t

R P N

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R P N

Receiving Inspection

Wrong material (Inks)

7

Supplier error/ No testing at Incoming

2

Certs of Conformance / Supplier evaluation

3

42

N/A

Material shelf life expired/nearing expiry

Yield impact/Line down Poor print definition Breakage problems Inconsistent element sizes

7

Supplier error

Receiving 2 inspection/Operator checks Print definition quality check. Bad batches returned to laser Scribe. Checks,SPC Check size at setup at Laser Scribe

3

42

N/A

Slag too high Scribe depth incorrect Scribe position

7

M Laser power settings 4

2

56

N/A

Laser Scribe

7 6

M

Laser settings

1 2

1 1

7 12

N/A N/A Increase scribe Variance for scribe depth,make Go/No Go depth, to be ECO'd Pbe gauge PM on block, Blocks to be and gauge implemented. MD Install & Commission Vision detection system SPOS July 2005

M Laser programming

Laser Scribe

Clean break on edge Print defect Voids, Bridging, Blobs etc

Mis reg. On print.

7

Shallow scribe M depth, worn breaker 4 block

Visual check

8

224

Complete

7

2

4

56

Print Top Term

Open Circuit/ Short Circuit

8

M

Print settings

3

Visual, X-Ray

Visual

8

192

Print