2009 Bendix Ppap Requirements Guidelines Rev 1-9-2009
2009 Bendix Ppap Requirements Guidelines Rev 1-9-2009
2009 Bendix Ppap Requirements Guidelines Rev 1-9-2009
Requirement
1. Design Records:
- For proprietary components / details
- For all other components / details
7. Control Plan
9. Dimensional Results
General Comments/Suggestions:
• 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).
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.
• 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.
Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
• 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.
1.0 SCOPE
The coating will degrade at temperatures above 140° F (46°C) with subsequent
loss of corrosion resistance.
2.0 PROPERTIES
2.1 Parts treated according to this specification shall have a uniform iridescent
to brown adherent coating. A porous, powdery coating is not acceptable.
The process shall supply the corrosion resistance described under
Qualification Requirements.
3.0 PROCESS
3.1 The parts shall be placed in baskets in a manner which will minimize air
pockets and provide best drainage, when possible. Configuration of some
parts may leave an unavoidable air pocket. Certain parts alodized by outside
vendors may be rack coated in which case rack marks must be in a non-
critical location. Sealing ring grooves and seat areas are typical critical
locations.
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AlliedSignal AUTOMOTIVE
Truck Brake Systems
Elyria, Ohio 44036 U.S.A.
3.3 The first rinse following alodizing is required to remove alodize solution
and stop the action. The second rinse is a hot water rinse required to set the
alodize and produce a cure. The process is as follows:
* This cleaning step may be omitted for castings coming directly from the
Plastic Impregnation Processing Line as the castings have already been
thoroughly washed as part of that process.
If the plastic resin impregnation system is used the chromate conversion film
shall be applied after impregnation (Section 11, BW-108-P).
SPEC. BW-128-P
4 SHEETS
SHEET NO. 2
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AlliedSignal AUTOMOTIVE
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Elyria, Ohio 44036 U.S.A.
Treated parts shall have a salt fog resistance at least four times that of
untreated parts.
4.3.1 After completion of the test, the panels should be cleaned in warm
water up to 100°F, blown dry with unheated air and examined for the
following criteria to pass the test.
SPEC. BW-128-P
4 SHEETS
SHEET NO. 3
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SPEC. BW-128-P
4 SHEETS
SHEET NO. 4
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Supplier Quality and Development
4. Design FMEA:
• 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.
Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
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.
7. Control Plan:
• Control plans for “families” of similar parts are acceptable if the new parts have been
reviewed for appropriate commonality.
• Regardless of the form used by the supplier, all elements of AIAG APQP
format must be addressed.
Note 1: Control plans for ‘families of parts are acceptable if the new parts
have been reviewed for commonality by the organization.
• 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.
9. Dimensional Results:
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.
Production Part Approval
NOTE: 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: 298725
SUPPLIER / VENDOR CODE: CODE: 909152 PART NAME: NAME: Crankcase Cover
INSPECTION FACILITY Acme DESIGN RECORD CHANGE LEVEL: ECL: Rev. 7
ENGINEERING CHANGE DOCUMENTS: ECN 69978
SPECIFICATION / QTY. ORGANIZATION MEASUREMENT RESULTS NOT
ITEM DIMENSION / SPECIFICATION TEST DATE OK
LIMITS TESTED (DATA) OK
1 5.64 unspecified tolerance 5.63 - 5.65 8/12/2002 5 5.633 Unspecified tol = .010 for 2 d.p. X
per ECN. See Engineering Change
Records, section 2.0
2 Dim "F" N/A N/A N/A N/A for this part number X
3-1 Dia. .346 +/- .007 .339 - .353 8/12/2002 5 .349 - .352 X
4-1 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .035 X
See CMM Report attached
5-1 Position = .015 M, A 8/12/2002 5 True Position = .020 X
See CMM Report attached
3-2 Diameter .346 +/- .007 .339 - .353 8/12/2002 5 .348 - .350 X
4-2 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .026 X
See CMM Report attached
5-2 Position = .015 M, A 8/12/2002 5 True Position = .020 X
See CMM Report attached
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. X
Edges Allowable
25 Treatment - Rust prevent per Spec. 8/12/2002 5 Rust Ban 392 used. Material is listed X
Spec BW-104-P on Bendix BW-104-P spec.
NOTICE
SUPERSEDES :
X
Written Date
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 the
individual casting drawing. All requirements herein must be met, in addition to all
other 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 castings
intended for production use and to serve as an aid to the casting suppliers.
4.0 GENERAL:
4.1 In those cases where a special flatness is required, it will be specified on the
drawing. 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 machining
fixture for first machining operations.
4.3 Die casters who intend to machine castings to obtain the specified as cast
dimensions must note this fact on their quotation sheet.
4.4 Key surfaces to be machined will be identified per Section 6.4 on both the
casting and machining drawings1. These machining drawings must be provided
to the die caster by SBM as part of the quotation process.
1
This is provided as an aid to the die caster in understanding BCVS casting requirements, even though the
casting supplier may not be doing the machining
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BCVS ENGINEERING STANDARD BW-111-ES
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5.0 POROSITY:
Die castings are never entirely free of porosity. However, this standard will attempt to
define the degree of porosity and imperfections permitted based on the functional need
of both the “as cast” and “as machined” part as it pertains to their use in the BCVS
organization.
5.1 Definitions:
5.1.1 Porosity: Irregular shaped voids in the die cast part as a result of gas
bubbles, impurities, shrinkage, movement of base material, etc.
5.1.2 Pore Size: The size of the porosity is defined as the largest dimension
of the pore; i.e. major diameter of a spherical or irregular shaped void,
or the longest dimensions of a crack-like void. Typical descriptions
are “pin-point” which are pores .020” (0.5mm) diameter or smaller,
and “pit type” which are pores larger than .020” (0.5mm) diameter.
6.0 REQUIREMENTS:
6.1 Working Pressure: Castings used in pneumatic control valves are designed for a
working pressure of 150 psi and must withstand a proof test2 of 600 psi without
failure. BCVS reserves the right to test components on production line or
laboratory equipment using either finished components or assemblies.
6.2 Leakage: The casting must be free of porosity, which may cause external
leakage.
Leakage determined to stem from air passage through gates, parting lines,
casting skin or other areas created by the casting process3 will be grounds for
rejection.
2
Frequency of proof testing is determined by statistical process control. Consult BCVS quality or 6 sigma
departments for further details.
3
Casting Process is further defined as the three processes of casting, annealing and cool down used in the
creation of the part. Optimized gating, reduced air entrapment, fewer cold shuts, reduced porosity and
optimized shot profiles are some of the parameters that can be optimized through the use of computer
simulation. Source: www/magmasoft.com or equal.
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BCVS ENGINEERING STANDARD BW-111-ES
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6.3 Porosity Levels: The level of porosity permitted will be determined by BCVS
and more than one level may be specified on a part. The level of porosity for
unspecified areas will be covered by a note on the casting and machining
drawings.
K-1: Machined surfaces shall not have pores larger than those in Level
1 or a frequency of pore occurrence greater than that of Level 1.
K-2: Machined Surfaces shall not have pores larger than those in
Level 2 or a frequency of pore occurrence greater than that of Level 2.
Unless otherwise specified on the casting drawing, the condition of all cast
surfaces must meet North American Die Casting Association Standard NADCA
G-6-6-94 Class 1. Identifying marks on castings must be completely legible
following cleaning and deburring procedures. If questions occur as to legibility,
they should be directed to BCVS engineering or quality department.
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BCVS ENGINEERING STANDARD BW-111-ES
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6.6 Flash4 Control:
Unless otherwise specified, the following requirements must be met:
6.6.2 Cored Hole and Insert Flash must be within 0.25 mm (.010”) of the die
cast surface (Ref: NADCA G-6-5-94).
6.6.3 Ejector Pin Flash must not exceed 0.60 mm (0.025”) height.
6.6.5 Flash from Gates and Overflows: Thick gates and overflows; trim
flash 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 and
the supplier (Ref: NADCA G-6-5-94).
6.7.1 The location and size of ejector pins will be mutually agreed upon by
BCVS 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 be
accepted.
4
Flash is defined as any excess cast metal the fills the voids created from improper die closure or die cavity
profile. It represents extra cost in the form of lost die casting pressure, extra metal, increased machining scrap
and potential operator harm among others. “ If you cannot take the time to correct the issue, then you cannot
afford to run the die” re: www/drdiecast.com
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BCVS ENGINEERING STANDARD BW-111-ES
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Bendix Commercial Vehicle Systems LLC
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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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Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
• Initial process studies are required where Bendix Special Characteristics are
applicable.
• 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 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.
• 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)
APPROVAL
SIGNATURE
Approve UPDATED Approve QR-0010
ISO QR 0010.msg
Bendix Special Chara
Revision 16:
Distribution section removed Frankfort and replaced with Bowling Green.
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:
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: 3 of 4
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: 4 of 4
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
Supplier Quality and Development
• 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)
• 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.
Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
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 Commercial Vehicle Systems LLC
Supplier Quality and Development
• 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.
Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
• 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 Commercial Vehicle Systems LLC
Supplier Quality and Development
• 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.
Reference QR-0010 and DPP 6.2.2.2 at element # 11, "Initial Process Study".
Reference the Bendix procedures BW-5348 and BW-5347 included in the BCVS
Business Manual.
• 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.
Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
• See Table in AIAG PPAP Manual – 4th Edition, for examples of changes requiring
notification and approval by Bendix.