ppap sample documents

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PRODUCTION PART APPROVAL PROCESS (PPAP) Supplier Name/Location/Supplier Code: Bourns Electronics Ireland Mahon Industrial Estate Blackrock Cork Ireland Supplier Part Number: Part/Family Description: Submission Date: PPAP DOCUMENT NO.:0009-P ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 1/29

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Page 1: PPAP sample documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

SSuupppplliieerr NNaammee//LLooccaattiioonn//SSuupppplliieerr CCooddee::

Bourns Electronics Ireland

Mahon Industrial Estate

Blackrock

Cork

Ireland

SSuupppplliieerr PPaarrtt NNuummbbeerr::

PPaarrtt//FFaammiillyy DDeessccrriippttiioonn::

SSuubbmmiissssiioonn DDaattee::

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 1/29

Page 2: PPAP sample documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

CCOONNTTEENNTTSS

TTSS1166994499 CCEERRTTIIFFIICCAATTIIOONN

PPAARRTT SSUUBBMMIISSSSIIOONN WWAARRRRAANNTT

DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART

CCOONNTTRROOLL PPLLAANN // MMEEAASSUURREEMMEENNTT SSYYSSTTEEMM SSTTUUDDIIEESS

PPAARRTT DDRRAAWWIINNGG && DDIIMMEENNSSIIOONNAALL RREEPPOORRTT

RREESSIISSTTAANNCCEE MMEEAASSUURREEMMEENNTT RREEPPOORRTT

MMAATTEERRIIAALL CCEERRTTIIFFIICCAATTIIOONN && IIMMDDSS AAPPPPRROOVVAALL

AAPPPPEEAARRAANNCCEE RREEPPOORRTT

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 2/29

Page 3: PPAP sample documents

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 3/29

Page 4: PPAP sample documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

PART SUBMISSION WARRANT

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 4/29

Page 5: PPAP sample documents

Bourns Part Number Customer Part Number

Dated

Additional Engineering Changes Dated N/A

Shown on Drawing Number Purchase Order No.

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Supplier Name

Customer Name/Division Street AddressBLACKROCK CORKCity State Zip

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

REASON FOR SUBMISSIONInitial submission Change to Optional Construction or MaterialEngineering Change's) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or additional Change in Part ProcessingCorrection of Discrepancy Parts produced at Additional LocationTooling Inactive > than 1 year Last PSW > 1 year old

Other - please specifyREQUESTED 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 RESULTSThe results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all drawing and specification requirements: (If "NO" - Explanation Required)

DECLARATIONI affirm that the samples represented by this warrant are representative of our parts, have been made to the applicableProduction Part Approval Process Manual 3rd Edition Requirements.

EXPLANATION/COMMENTS:

Print Name Title Fax No.

Supplier Authorized Signature Date

Supplier E-mail Address

FOR CUSTOMER USE ONLY (IF APPLICABLE)Part Warrant Disposition:

Customer Name Customer Signature Date

ua tities until functional approval or waiver is nom customer.

Part Submission Warrant

Sample co ordinator

BOURNS ELECTRONICS

MAHON INDUSTRIAL ESTATE

NONE

Phone No.

Safety and/or Government Regulation

Engineering Drawing Change Level

Dimensional Materials/Function Appearance

Yes No

NoYes

YES NO

Approved Rejected

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 5/29

johno
New Stamp
Page 6: PPAP sample documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

DDEESSIIGGNN FFMMEEAA // PPRROOCCEESSSS FFMMEEAA // PPRROODDUUCCTTIIOONN PPRROOCCEESSSS FFLLOOWW CCHHAARRTT

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 6/29

Page 7: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)

Bourns Electronics (Irl) FMEA Number : DFM-C0002

FMEA Revision : Rev G

Failure Mode & Effects Analysis ECO No.: 05-0046Item : Automotive Fuel Level Sensor Design FMEA Prepared By : S P O'SullivanModel :3710X-XXX, 3714X-XXX FMEA Date (Rev.) 21-Feb-05Core Team : JL, MO'B, SPOS, PB, EO'R FMEA Date (Orig.) 01-Aug-96

Design Functions & Requirements

Potential Failure Mode

Potential Effect(s) of

Failure

Sev

Class

Potential Cause(s) /

Mechanism(s) of Failure

Occur

Current Design Controls

Detect

RPN

Recommended Actions

Responsibility & Target

Completion Date

Actions Taken

Sev

Occ

Det

RPN

Resistor Too Low Gauge Inaccuracy 7 M Incorrect Design 4 PPAP sample

qualification 1 28

Too Low Gauge Inaccuracy 7 M Low ohms/square 4 PPAP sample

qualification 1 28

Too high Gauge Inaccuracy 7 M Incorrect Design 4 PPAP sample

qualification 1 28

Too high Gauge Inaccuracy 7 M Low ohms/square 4 PPAP sample

qualification 1 28

Resistor value Drift Gauge Inaccuracy 6 M Material unsuitable

for environment 5PPAP sample

qualification, customertests

2 60

Termination Open circuit No gauge reading 8 C Incorrect Design 5

Design Rules, PPAP, Gerber View, Artwork

Inspection1 40

Open circuit No gauge reading 8 C

Incorrect material selection, Premature

element wear2 PPAP sample

qualification 2 32

Probe mark on resistorcard.

Eratic opencircuit 8 C

Positioning of probe points on wiper travel

area.4 Not listed. 5 160

Include in the product template for all product that requires probing

near the potential wiper

John O'Connell 16-1-05

Template updated, design

procedure

8 1 5 40

Incorrect Circuit Layout

Incorrect Output 7 C Design Errors 7 PPAP sample

qualification 1 49 12/01/2005

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 7/29

Page 8: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)

Design Functions & Requirements

Potential Failure Mode

Potential Effect(s) of

Failure

Sev

Class

Potential Cause(s) /

Mechanism(s) of Failure

Occur

Current Design Controls

Detect

RPN

Recommended Actions

Responsibility & Target

Completion Date

Actions Taken

Sev

Occ

Det

RPN

Termination Shorts circuit Erratic output 7 c Incorrect gap between tracks 7 Design Rules, PPAP,

Artwork Inspection 1 49

Short circuit Erratic output 7 c Incorrect Design 3 Design Rules, PPAP, Artwork Inspection 2 42

Resistor value drift Erratic gauge output 7 m Material unsuitable

for environment 5PPAP sample

qualification, customertests

2 70Reliability testing to be

carried out to verify material suitability

Tom Burke 2003/4Completed, Drift within

specification.7 4 2 56

Substrate Dimensions Parts not to sizeIncompatible

with customers assembly

8 M Design Errors 5

Drawing checked by Design Engineer,

PPAP Sample Qualification

1 40

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 8/29

Page 9: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)FMEA Number : PFM-C0003

FMEA Revision : Rev MECO No.: 05-0132

Prepared By : S P O'SullivanFMEA Date (Rev.) 22-Jun-05

Item Automotive Fuelcard Process Responsibility Bourns Ireland Mfg Eng FMEA Date (Orig.) 27-May-99Model 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

Process Functions & Requiremen

ts

Potential Failure Mode

Potential Effect(s) of

Failure

Sev

Class

Potential Cause(s) /

Mechanism(s) of Failure

Occur

Current Process Controls

Prevention

Current Process Controls Detection

Detect

RPN

Recommended Actions

Responsibility & Target

Completion Date

Actions Taken

Sev

Occ

Det

RPN

Receiving Inspection

Wrong material (Inks)

Yield impact/Line

down7 Supplier error/ No

testing at Incoming 2Certs of

Conformance / Supplier evaluation

3 42 N/A

Material shelf life expired/nearing

expiry

Yield impact/Line

down7 Supplier error 2

Receiving inspection/Operator

checks3 42 N/A

Slag too high Poor print definition 7 M Laser power settings 4

Print definition quality check. Bad batches returned to

laser Scribe.

2 56 N/A

Laser Scribe Scribe depth incorrect

Breakage problems 7 M Laser settings 1 Checks,SPC 1 7 N/A

Scribe position Inconsistent element sizes 6 M Laser programming 2 Check size at setup

at Laser Scribe 1 12 N/A

Laser Scribe Clean break on edge

Mis reg. On print. 7 M

Shallow scribe depth, worn breaker

block4 Visual check 8 224

Increase scribe depth,make Go/No Go

gauge PM on block, and gauge

Variance for scribe depth, to be ECO'd Pbe

Blocks to be implemented. MD

Complete 7 2 4 56

Print Top TermPrint defect -

Voids, Bridging, Blobs etc

Open Circuit/ Short Circuit 8 M Print settings 3 Visual, X-Ray Visual 8 192 Install & Commission

Vision detection system SPOS July 2005

Print Top term Wrong Ink used. Reliability issue 8 M Wrong ink selected. 4 Ink jar label, PO stating ink type 5 160

Templates filed by ink type, Segration of ink

types. Cross referance of lot numbers to COC's

in QA.

Mike D. July 16. Sean P. July 16 Completed 8 2 4 64

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

(PROCESS FMEA)

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 9/29

Page 10: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)

Print Top term Ink thickness incorrect Reliability issue 8 M Wrong setup 2 Ink thickness

measuring machine Dektak 2 32

Templates filed by ink type, Segration of ink

types. Cross referance of lot numbers to COC's

in QA.

Mike D. July 16. Sean P. July 16 Completed 8 2 4 64

Print Top TermPrint defect - Voids, Bridging, Blobs etc

Open Circuit/ Short Circuit

8 M Design Problems 6 Design Rules 2 96Update design rules to

reflect actual print capability

JL; PB; EO'R; Customer. ECD Wk 26

2001Completed 8 4 2 64

8 M Screen problems 7 Visual 8 448

Add checks to Procedure. Change to 280 Mesh for screens. Verify effectiveness.

Add shorts / open tester

Procedures, Mesh PB, ECD Wk 28;

Effectivness, PB, ECD Wk 28; Tester, SPO'S,

ECD Wk 25 2001

Procedures / Mesh

change completed

8 4 2 64

Print alignmentOpen Circuit on part of wiper stroke

8 M Incorrect print setup 5 Visual 8 320Update procedures to

incorporate set up alignment checks

P.B. ECD Wk 13 2001 Procedure Updated 8 4 2 64

Dry & Fire top term Scratches of term Open Circuit/

Short Circuit 8 M Parts piling up at end of dryer 4 Visual & laser trim 5 160

Update procedure to scrap plates which pile

up.

Procedure PB, Wk 20, 2001 Data does not

support need for scraping plates, revised proceedure. Week 25

2002

Procedure Updated 8 4 1 32

Resist Print Resist Voids TR values out of spec 8 Mi Incorrect setup 3

TR setup check. Resistance check at

laser trim.1 24 N/A

Print misaligned Visual & Elect failure 7 M Incorrect setup 3 Visual & electrical

check at laser trim 2 42 N/A

Surface Treatment 1 Wiper Stiction 7 Procedure 4 112

Shortened lifetime 5 Routing 4 80

Reduced track thickness 5 Torque check 3 45

Debris on part 5 45

Smearing of ink 5 45

Broken plates 5 45

Surface Treatment process goes in-line.

Operating pressure too high

Pat Bradley 31st Sept 2005Operator ErrorMissed Process 4

Incorrect setup 3

Current check 3

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 10/29

Page 11: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)

Wiper Stiction 7 Torque check 3 63

Shortened lifetime 5 Current check 3 45

Wiper Stiction 7 56

Shortened lifetime 5 40

Incorrect Active Element Contamination 5 Multiple materials in

stock 4 Stock only 1 material 3 60

Active Element Damage Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42

Contamination on tooling

Contaminated parts 5 No active cleaning 4 Air knife 3 60

Wrong plate orientation

Ink smearing/shorti

ng5 Operator error 3 Procedure/diagrams 3 45

Surface Treatment 2 Wiper Stiction 7 Procedure 4 112

Shortened lifetime 5 Routing 4 80

Reduced track thickness 5 Torque check 3 45

Debris on part 5 45

Smearing of ink 5 45

Broken plates 5 45

Wiper Stiction 7 Torque check 3 63

Shortened lifetime 5 Current check 3 45

Wiper Stiction 7 56

Shortened lifetime 5 40

Incorrect Active Element Contamination 5 Multiple materials in

stock 4 Stock only 1 material 3 60

Active Element Damage Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42

Contamination on tooling

Contaminated parts 5 No active cleaning 4 Air knife 3 60

Wrong plate orientation

Ink smearing/shorti

ng5 Operator error 3 Procedure/diagrams 3 45

Operating pressure too low Incorrect setup 3

Operating pressure too high

Worn Active Element

Active element wearing with use 4 PEMAC 2

3Current check

Incorrect setup 3

4

4Operator ErrorMissed Process

Incorrect setup 3Operating pressure too low

Worn Active Element

Active element wearing with use PEMAC 2

Surface Treatment process goes in-line.

Pat Bradley 31st Sept 2005

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 11/29

Page 12: PPAP sample documents

PRODUCT PART APPROVAL PROCESS(PPAP)

Laser trim Untrimmed parts

Customer reject - can

cause end user failure

7 C Mishandling & m/c malfunction 5

Visual control & colour coded

storage of trimmed/untrimmed

parts

8 280 Install 100% autotester after laser Trim

WK, LC, TH, ECD - Week 25 2000

Eliminated requirement for colour code

racks.Week 15 2002

w 7 4 1 28

Dielectric Print, and Cure

Poorly Covered resist

Customer reject - can

cause end user failure

3 Mi Incorrect print set up. 3 Visual 8 72 n/A

Solder Stencil print, and wash

Poorly Covered term pad

Customer reject. 3 Mi Incorrect Stencil set

up 3 Visual 8 72 N/A

Poorly washed part

Customer reject, potential

corrosion7 Mi Incorrect

washing,check 5 Visual 8 280 Investigate potential for Corrosion Sean S.Week 05 Completed 1 4 7 28

Singulate into units Bad breaks

Customer cannot use

parts7 Mi Manual Breaking 5 Op - visual QA -

sample 8 280 Install breaker in shorts / open tester

TH, ECD - Week 25 2001 Completed 7 2 5 70

Machine dynamic test Shorts, Opens Customer

Issues 7 C Incorrect set up.Machine fault 3 Electrical test. 5 105

At set up 1 L/T failure to be taken, and tested to

verify failure

July 16 2003 Sean P., Mike D. Completed 7 3 1 21

Final Process Inspection No Inspection Customer

issues 7 C Poor training / Operator Error 3 Training/SDWT 2 42 n/A

Packing Wrong labels Shipment Return 7 Operator error 2

Inspecting 1 PO at a time. QA checks.

Op checks2 28 N/A

Wrong Qtys Customer dis-satisfaction 7 Operator Error 2

Inspecting 1 PO at a time. QA checks.

Op checks2 28 N/A

Mixed parts Customer dis-satisfaction 7 Operator Error 2

Inspecting 1 PO at a time. QA checks.

Op checks2 28 N/A

Final QA Inspection

Defective parts escaping

Customer complaints 7 Inspector error 2 QA Inspection 2 28 N/A

Shipping More than 1 P/N per box

Customer dis-satisfaction 5

Poor communication at shipping/packing

of customer requirement

4 Shipping checks 3 60 N/APPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 12/29

Page 13: PPAP sample documents

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 13/29

Page 14: PPAP sample documents

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 14/29

Page 15: PPAP sample documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

CCOONNTTRROOLL PPLLAANN // MMEEAASSUURREEMMEENNTT SSYYSSTTEEMM SSTTUUDDIIEESS

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 15/29

Page 16: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

FUEL CARD PRE-LAUNCH CONTROL PLAN P ROTOTYPE PRE-LAUNCH PRODUCTION KEY CONTACT DATE ORIGINAL DATE REVISION

CONTROL PLAN NUMBER MCP-0002 Sean P. O’ Sullivan 02.09.2003 26.05.2005

PART NUMBER LATEST REVISION CORE TEAM CUSTOMER ENGINEERING APPROVAL DATE IF REQD 37XXX-XXX-XXX REV. B (ECO #05-0111) SPOS , Pat Bradley, Sean Sugrue ,Peter Berry PART NAME DESCRIPTION SUPPLIER/PLANT APPROVAL DATE CUSTOMER QUALITY APPROVAL DATE IF REQD

FUELCARD SUPPLIER/PLANT SUPPLIER CODE OTHER APPROVAL DATE (IF REQD) OTHER APPROVAL DATE IF REQD

BOURNS ELECTRONICS IRELAND

Process Flow Machine, Device,

Characteristics Methods Reaction if out-of-control

No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

11

12

Receiving Inspection

N/A Ceramic Mfg Process

As per Certificate of Conformance, Visual& Dimensions

Appropriate part drawing as per BOM.

Micrometer, Tool Scope, Smart scope

See RP 003

Every ship- ment

Review C of C,Material history,Usage in production

Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.

21

22

Receiving Inspection

N/A Conductor Mfg process

As per Certificate of Conformance

C of C

Review Certificate of Conformance

N/A Every ship- ment

File C of C Comply to MM-C6015

Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.

31 32

Receiving Inspection

N/A Resist mfg Process

As per Certificate of Conformance

C of C

Review Certificate of Conformance

N/A Every ship- ment

File C of C Comply to MM-C6015

Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.

51

52

Screen Manufacture

Screen Stretcher & Exposure unit

Bourns Screen Manufacturing

Screen Blockage & shorts. Screen Tension.

TCPH3

Visual Inspection. Tensiometer.

All Screens

All Screens

Check vs TCPH3

Reject Screen

61 62

Receiving Inspection

N/A Shipping tray mfg process.

N/A – Ship to stock

Appropriate part drawing as per BOM.

N/A N/A Ship To stock

N/A Material rejected from floor On WIP. Reject material, impound and Identify with SCAR no. RTV.

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 16/29

Page 17: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered

Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

150

150

160

160

Laser-Scribe Inspection

Laser Scribe

Camber guage C02 Laser scriber

Ceramic Mfg. Process Laser scribing

Camber Scribe depth

+

PS-C4000 PS-C4000

Camber Go / No Go guage Toolmakers Scope

5% of ship- ment 1 plate

Every ship- ment Every 100 plates

Log in L/S log book Log in MFG050 Pre-control SPC Chart (MFG217)

Inform Mfg. Engineer for dispositio Do not process with order. Green Zone = Normal production. White Zone = Continue but call Technician Red Zone = Stop and inform Supervisor.

Scribe Position PS-C4000 & Product Template

Toolmakers Scope At set up + start of every P.O. Record resultsOn MFG 050

See PS-C 4000

At setup And start of every P.O. Record results On MFG 050

Check Vs Product template

Re-check X+Y scribe m/c settings. If problem still exists call technician.

150

160

Laser Scribe C02 Laser scriber Laser scribing

Break out Dimension

+

Product template Vernier Calipers

30 Pieces,

6 Monthly.

Cpk >1.5. Calculate with SPC Kiss. Record results onNetwork server

Manufacturing Engineer to Review and decide on appropriate corrective action if required.

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 17/29

Page 18: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered

Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method Ink Thickness

+

Limits as per layer Card SI-C-4193

Automated Vision system or X-ray machine

1 plate

At setupAnd Every 100 plates

Check results vs Layer Card, log on QA1000

At set-up- Change squeegee, Screen, check pressure - as required. In Process- Isolate product and inform Supervisor & Engineering Disposition : (a) Confirm product outside specification. (b) If outside specification scrap affected units

in order.

250 260 Term Print Screen Printer Screen Printing

Alignment & Gap Width

+

Product template Automated Vision systemOr shadow graph

1 plate

At setupAnd Every 100 plates

Check results Vs Product template Log on QA1000

Product template Smartscope 30 Pieces,6 gap measur-ements, 1 align-ment measu-rement.

Every 6 Months.

Cpk >1.5. Calculate with SPC Kiss. Record results on Network server

Manufacturing Engineer to Review and decide on appropriate corrective action if required.

270 280 Term Dry & fire Drier & furnace Drier & furnace

Settings / profile Thickness +

PS-C4088

Dektak Print Thickness

Meter 1 plate

Every 200

plates

Log Results on QA1000. Check vs

spec

Impound P.O. and inform engineering for disposition.

290 300 Visual Inspection

Mantis Inspection Station Visual inspection Visual Defects +

PS-C4088 Visual check

As per PS-

C4088

As per PS-

C4088

Check against PS-C4088,

Log rejects on plate.Units rejected.

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 18/29

Page 19: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered

Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method 450

460 Mix Inks

& qualify Ink

Printer, drier, furnace & Furnace-room data-base / multimeter

Ink Mixing &

Ink qualification

Resistance

+

OP-4033C &

ME0032C

Furnace room data-base / Multimeter

As Per

Ink qual.

requirement

As Per

Ink qual.

requirement

Check program results vs TF

database

Re-blend & Re-qualify inks.

470 480 Resist Print Screen Printer Screen Printing Alignment +

Product Template Shadow graph 1 plate At set-up & every 100

plates

Record results on QA1000.

Check vs Template

Set-up = Reject if outside tolerance. Adjust printer and verify alignment within limits. In Process = Isolate product since last measurement, screen for out of spec product and scrap

490 500 Resist Dry & fire

Drier & furnace

Drier & Furnace settings /profile

Resistance +

PS-C4088 Furnace-room database &/ Multimeter

1 plate Every 100

plates

Log Results in Furnace-room database or on

MFG194, if D-Base is not available.

Inform Supervisor and Printing Operator. Disposition : (a) Supervisor to detemine

if Yield loss at Laser is acceptable. If Not Scrap entire order.

(b) Inform Ink Qual Operatorand retarget ink prior to processing further orders.

600 610 Surface Treatment 1

Surface treatmentmachine

Speed Motor Current Torque PS-C4232 Offline

Calibration 1 plate Weekly Fuelcard Torque Fixture

Inform Supervisor. Stop Brushing process till corrected.

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 19/29

Page 20: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered

Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

800 810 Laser Trim Laser Trim Machine

Trimming TR Value Resistance C PS-C4197 Multimeter

5 trimmed

units

At set-up and every

30 mins

Check vs Laser Trim Database

Visually inspect laser cut to determine cause of problem. Check all parts back to last check. Mark rejects with marker.

PS-C4197 Trim Database 6 Monthly

Cpk > 1.66.

Review Cpk

results In trim

database.

Manufacturing Engineer to review and decide onappropriate correctivaction if required.

Set-up = Reject if outside tolerance. Adjust printer and verify alignment within limits. In Process = Isolate product since last measurement, screen for out of spec product and scrap

Laser Trim Laser Trim Machine

Finish quality

Kerf cleanliness and Position C PS-C4197

Microscope Vision System

5 trimmed

units

At set-up and every

30 mins

Visual Inspection

Determine cause of problem. Check all parts back to last check. Mark rejects with marker.

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 20/29

Page 21: PPAP sample documents

PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered

Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

815 816 Solder print on pads

Stencil printer & Vitronics oven

Solder paste printing

Solder coverage and alignment

+

PS-C4219 PS-C4218 Visual 100% 100% Visual Check

Call a technician if coverage or alignment are not correct

820

830 Final Test TR Meter Final Test Resistance Value C Product Template

TR Meter

50 units 100% TR Test.

Notify NPI Program Manager Foe Eng. Analysis.

900 910

Final Inspection

N/A

Dimensional Checks

Dimensional

Product Template

Customer Drawing

Go / No Guage

Smartscope

50 units

2 units

100% 100%

Guage

Record results

Notify NPI Program Manager For Eng. Analysis Notify NPI Program Manager For Eng. Analysis

Final Inspection N/A Visual Visual defects

e.g. short-circuits As per Visual

Standards in MM-C6804

Visual Analysis 100% 100% Visual check

Reject batch and re-screen

Final Inspection N/A N/A Packaging &

Documentation MM-C6804 Visual As perMM-

C6804100% Visual check

Reject batch send for Screening.

920 930 Shipping N/A N/A Packaging & Documentation MM-C7026 Visual

As perMM-

C7026100% Visual check

Reject shipment, re-pack. Inform supervisor.

Special Characteristics Codes (Class)

C

Critical

+ Major (Significant)

_ Minor

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 21/29

Page 22: PPAP sample documents

Piece Part, Model, or Part Number: Division: Quarter & Year:

FUEL CARD Trimpot Q03 '05Measurement Systems Analysis Statistical Process Control Process Capability SPC CONTROL

Critical Characteristic Type & Model GR&R Date of Last Chart Sample Sample DOE FOR LAST 3 MONTHSand Specification of Gage % Mea. Study Type Size Frequency Cp Cpk Status

VISUAL AND DIMENSIONAL SMARTSCOPE 9.20% 29/06/2004 NONE NONE NONE n/a n/a n/a none none n/a VERIFICARIONSCRIBE DEPTH RHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 2.31 2.08 N/A IN IN IN0.010" +/-0.002 INCH SCOPE CHART 4 HRSSCRIBE DEPTH LHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 1.76 1.64 N/A IN IN IN0.010" +/-0.002 INCH SCOPE CHART 4 HRSTERM WIDTH (wet) BEI VISION 13.00% 27/09/2005 NONE 1 PLATE EVERY 100 1.73 1.18 N/A none none n/a.006'+/-.001 SYSTEM PLATES TERM THICKNESS DEKTAK 21.50% 29/06/2004 NONE 1.84 1.12 N/A none none n/a

TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 1.50 1.44 N/A none none n/aWIDTH (.016+/-.003 INCH) SYSTEM PLATESTERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 0.93 0.92 N/A none none n/aLENGTH (.010"+/-.003 INCH) SYSTEM PLATES

RESISTANCE MULTIMETER 0.20% 05/07/2004 NONE 2.90 1.68 n/a none none n/akiln pre trim HP34401aLASER TRIM MULTIMETER 8.60% 29/06/2004 NONE 3.13 2.74 N/A none none n/aRESISTANCE KEITHLEY 2010QA DIMENTIONAL VERNIER 15.95% 26/07/2005 NONE 2.09 1.62 N/A none none n/aLENGTH(38.1mm +0.25 /-0.05) MITUTOYO 500-191QA DIMENTIONAL VERNIER 17.72% 26/07/2005 NONE 2.37 1.33 N/A none none n/aWIDTH (16.40mm +.25/-.05) MITUTOYO 500-191QA DIMENTIONAL VERNIER 11.82% 29/06/2004 NONE 4.00 3.60 N/A none none n/aTHICKNESS (.63mm=/-.07mm) MITUTOYO 500-191

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PRODUCTION PART APPROVAL PROCESS (PPAP)

PPAARRTT DDRRAAWWIINNGG && DDIIMMEENNSSIIOONNAALL RREEPPOORRTT

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 23/29

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PRODUCTION PART APPROVAL - DIMENSIONAL RESULTS Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 BCustomer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM

Measurement Method : SmartscopeUnit 1 Unit 2 Unit 3 Unit 4 Unit 5

Item Nominal Tol + Tol - Units Min Max Special Actual OK Actual OK Actual OK Actual OK Actual OK

DIM1 35.9 0.10 -0.10 35.8958 35.9182 35.9179 35.9179 35.9182 35.9056 35.8958

DIM2 16 0.10 -0.10 15.9993 16.0097 16.0001 15.9998 15.9995 16.0097 15.9993DIM3 0.635 0.05 -0.05 0.6100 0.6200 0.6200 0.6200 0.6200 0.6100 0.6100DIM4 15.85 0.05 -0.05 15.8006 15.8618 15.8073 15.8096 15.8618 15.8006 15.8252DIM5 4.45 0.10 -0.10 4.3796 4.4544 4.4544 4.3836 4.3796 4.4085 4.4057DIM6 3 0.15 -0.15 2.9972 3.0282 2.9972 3.0048 3.0282 3.0044 3.0055DIM7 5 0.15 -0.15 4.9931 5.0386 4.9931 5.0130 5.0386 5.0005 5.0311DIM8 0.3 0.10 -0.10 0.8164 0.8216 0.8191 0.8174 0.8164 0.8216 0.8194DIM9 14.5 0.20 -0.20 14.5069 14.5475 14.5475 14.5069 14.5220 14.5117 14.5309

DIM10 16.5 0.05 -0.05 16.5414 16.5472 16.5472 16.5436 16.5414 16.5447 16.5444DIM11 18.5 0.25 -0.25 18.4795 18.5144 18.5144 18.4795 18.4934 18.4920 18.5043DIM12 2.9 0.10 -0.10 2.8466 2.9076 2.8618 2.8581 2.9076 2.8466 2.8581DIM13 5.85 0.15 -0.15 5.8601 5.9043 5.8601 5.8882 5.9043 5.8789 5.8887DIM14 53.19 0.50 -0.50 53.5253 53.6889 53.6889 53.5253 53.6193 53.6134 53.5282DIM15 56.19 0.50 -0.50 56.2135 56.3012 56.3012 56.2245 56.2135 56.2358 56.2272DIM16 73.87 0.50 -0.50 73.8953 73.9500 73.9500 73.9241 73.8977 73.9106 73.8953DIM17 89.02 0.50 -0.50 89.0379 89.0938 89.0749 89.0938 89.0621 89.0604 89.0379DIM18 104.45 0.50 -0.50 104.4698 104.5508 104.5065 104.5508 104.4941 104.5221 104.4698DIM19 109.9 0.50 -0.50 109.9144 109.9994 109.9399 109.9994 109.9605 109.9684 109.9144DIM20 122.42 0.50 -0.50 122.4417 122.5419 122.4500 122.5419 122.4979 122.5010 122.4417DIM21 126 0.50 -0.50 126.2407 126.4399 126.2786 126.4399 126.2407 126.3801 126.3533

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PRODUCTION PART APPROVAL PROCESS (PPAP)

RREESSIISSTTAANNCCEE MMEEAASSUURREEMMEENNTT RREEPPOORRTT

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 24/29

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Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 BCustomer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM

Measurement Method : Keithley MultimeterRST.# R1 R2 R3 R4 R5 R6 R7 R8NOM. TR. Ω 2.00 5.00 17.00 32.50 50.00 70.00 120.00 125.00Tolerance + 0.50 0.50 0.50 0.50 0.50 0.70 1.20 1.25Tolerance - -0.50 -0.50 -0.50 -0.50 -0.50 -0.70 -1.20 -1.25

1 1.9571 5.0455 16.958 32.466 49.961 69.935 120.03 1252 1.9586 4.9708 16.975 32.454 49.964 69.911 120.03 125.033 1.9641 5.1183 16.969 32.454 49.98 69.916 120.04 125.074 1.9654 5.1171 16.964 32.464 49.981 69.98 120.1 125.075 1.9668 4.9605 16.968 32.469 49.979 69.901 120 125.016 2.0146 5.0553 16.989 32.493 50.032 69.955 120.07 125.057 1.9978 5.1506 16.991 32.497 50.008 69.97 120.07 125.068 1.9961 5.0464 17.011 32.502 50.018 69.969 120.13 125.079 1.996 5.0308 17 32.484 50.074 69.94 120.07 125.07

10 2.0174 5.0305 17.009 32.52 50.027 69.999 120.09 125.0911 1.9954 5.1542 16.997 32.504 50.012 69.977 120.09 125.0412 2.001 5.0454 16.994 32.503 50.015 69.949 120.08 125.0613 1.9976 5.0098 17.002 32.493 50.013 70.031 120.06 125.0114 1.9979 5.0602 17.001 32.514 50.021 69.942 120.08 125.0915 1.9835 5.0899 16.987 32.511 50.003 69.994 120.08 125.1116 2.0091 5.0402 17.003 32.502 49.99 69.955 120.14 125.1217 1.9934 5.1129 17.009 32.5 50.012 69.949 120.1 125.118 1.9944 5.1028 17.001 32.499 50.012 69.947 120.09 125.0919 2.0045 5.031 17.002 32.498 49.982 69.975 120.03 125.0420 1.9859 5.0445 16.988 32.496 49.994 70 120.09 125.121 1.9793 4.9934 16.984 32.487 50.007 69.893 120.04 125.0122 1.9756 5.0825 16.98 32.48 49.991 69.963 120.1 125.1123 1.966 4.9686 16.984 32.489 49.977 69.965 120.04 125.0324 1.961 5.0874 16.977 32.469 49.978 69.947 120.07 125.0925 1.9652 4.9777 16.974 32.491 49.981 69.924 120.08 125.0426 2.0004 5.1785 16.995 32.491 50.004 69.959 120.01 125.0227 1.9807 5.0044 16.997 32.485 50.003 69.965 120.04 125.0328 1.9805 5.1058 17.002 32.506 49.995 69.959 120.1 125.0729 1.9871 5.0871 16.983 32.501 50.005 69.974 120.09 125.0830 2.0017 5.0724 16.992 32.498 50.006 69.923 120.11 125.0731 1.9915 4.9903 16.993 32.497 50.005 69.954 120.07 125.0532 1.9876 5.1488 16.998 32.501 50.008 69.949 120.15 125.0833 1.9712 4.9906 16.99 32.484 49.99 69.943 120.07 125.0734 1.9749 4.9797 16.983 32.477 49.985 69.961 120.1 125.135 1.981 5.0072 16.986 32.484 49.985 69.935 120.13 125.0736 1.9918 5.1638 16.983 32.492 50.019 69.94 120.1 125.0737 1.9996 5.0066 16.992 32.501 50.005 69.993 120.06 125.0738 1.9733 5.0317 17.004 32.501 50.021 70.005 120.13 125.0939 1.9723 5.1322 16.985 32.47 50.022 69.943 120.09 125.0640 1.9928 5.1354 16.999 32.481 49.998 69.941 120.05 125.0341 2.2248 5.2413 17.203 32.689 50.208 70.169 120.3 125.2942 2.2009 5.2474 17.193 32.693 50.204 70.156 120.24 125.2243 2.1958 5.2742 17.193 32.705 50.213 70.122 120.27 125.2944 2.2068 5.2529 17.202 32.709 50.23 70.153 120.34 125.3145 2.2201 5.2914 17.223 32.718 50.215 70.257 120.29 125.2846 1.9753 5.0116 16.986 32.488 49.997 69.887 120.07 125.0247 1.9717 5.0925 16.971 32.5 49.986 69.962 120.09 125.0648 1.982 5.0394 16.987 32.481 49.988 70.116 120.04 125.0249 1.9775 5.021 16.968 32.484 49.98 69.939 120.05 125.0350 1.9794 5.1157 16.991 32.476 50.018 69.957 120.11 125.06

MEAN 2.01 5.08 17.01 32.51 50.02 69.98 120.10 125.08Std. Dev. 0.07 0.08 0.07 0.07 0.07 0.08 0.07 0.07

Max. 2.22 5.29 17.22 32.72 50.23 70.26 120.34 125.31Min. 1.96 4.96 16.96 32.45 49.96 69.89 120.00 125.00

Cm 2.39 2.00 2.52 2.52 2.47 3.09 5.53 5.72Cmk 2.36 1.68 2.47 2.46 2.36 3.00 5.08 5.35

NAME: Caroline Hickey DATE: 10/11/2005

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PRODUCTION PART APPROVAL PROCESS (PPAP)

MMAATTEERRIIAALL CCEERRTTIIFFIICCAATTIIOONN && IIMMDDSS AAPPPPRROOVVAALL

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 25/29

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PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 26/29

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PRODUCTION PART APPROVAL PROCESS (PPAP)

AAPPPPEEAARRAANNCCEE AAPPPPRROOVVAALL RREEPPOORRTT && PPAACCKKAAGGIINNGG DDEESSCCRRIIPPTTIIOONN

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 28/29

Page 32: PPAP sample documents

PART NO.

SUPPLIER NAMEIRL

SUPPLIER CODE DSZ QA

PASS FAIL

CUSTOMER REPRESENTATIVE SIGNATURE DATE

MARK MARTIN

INSPECTED BY TELEPHONE NO.

00353 21 4515 381

OTHER

COMMENT

CUSTOMER USE ONLY

CONTAMINATION

DRAWING NO.

Fuelcard Appearance Approval Report

BOURNS ELECTRONICSMANUFACTURING LOCATION

BLISTERS

SCRATCHES

MARKINGS

JAGGED EDGES

VOIDS

PROTRUSIONS

SOLDER COVERAGE

DEFECT DESCRIPTION

CAROLINE HICKEY

SMEARS/SMUDGES

OPEN CIRCUITS

SHORTS

PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 29/29