Supplier Kick-Off Review Document - Yeemak - 20230811

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Public #_x000D_

SUPPLIER KICK-OFF REVIEW NOTES & MINUTES

Review Date: 2023.8/11 Representatives (Name): Approval Signature


Item Description: Buyer (Inalfa): Seokhyeon, Kang
Item Number: Design Engineer (Inalfa): Sunguk, Cho
Item Revision: A00 Supplier Quality (Inalfa): Youngjune, Han
Drawing No. / DMU Status: Tooling Mgr / Engineer (Inalfa) Last DR before K/O:
Logistics (Inalfa) Last DR before K/O:
3D File Name / Date:
Mandatory => Purchase Manager Project - SQD Manager - Manager Project Engineering
Supplier (Company):YEEMAK
Review Type (Check One): Sales Manager (Supplier):
Concept Engineer (Supplier):
Prototype Tool Release Quality Rep (Supplier):
Production Tool Release Logistics (Supplier):
Eng. Chg. (Update Applicable Items) Other (Supplier):
Engineering change description (if applicable):

STATUS OVERVIEW:

Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
Section #1: Design - Drawing and Notes (Engineering)
1.1 Text Block: Symbol Definition
1.1.1 Is the meaning of F and C No issue
symbols with corresponding measurement
requirements understood as shown on the "KEY Approved
CHARACTERISTICS MATRIX" tab?

1.2 Text Block: CAD Model Standards


1.2.1 Review, and confirm notes for CAD model No issue
standards are acceptable and clear:
- The drawing is master.
- The CAD model is master, only, for all
unspecified information and does not include
allowance for process variables such as
shrinkage, warpage or other material
considerations. It also may not include fillets,
radii or draft angles which are specified on the Approved
drawing.
- The CAD Model defines the "nominal" size
and shape of the Finished Component.
- Are there any issues?

1.2.2 Review 3D models (radii, fillets, draft angles, No issue


formability, etc.).
- Are there any issues?

Approved

1.3 Text Block: Material and Process Restrictions


1.3.1 Are all of the materials including coatings free of No issue
prohibited substances per the latest GADSL January 1, 2020
(Global Automotive Declarable Substance List,
www.gadsl.org)? Approved
- Which revision was used for verification?
- Is it the latest version?

1.3.2 Who is the supplier's IMDS Coordinator? No issue


- Are Inalfa submission requirements clear? ( We will register with IMDS and submit it.)
- P/N format for submission is 8 digit item
number, plus Alpha revision,
e.g. 00000000X Approved
(Per instructions on Supplier Portal).
-Is Inalfa ID provided for IMDS submissions?

1.4 Text Block: Standards, Specifications, & Performance / Test Requirements


1.4.1 -Has the supplier obtained and reviewed all No issue
specifications and standards shown on the
drawing and "TEST REQUIREMENTS" tab?
-Does the supplier understand all test methods
(i.e. sample size, length of test, test equipment Approved
and procedures, etc.), and acceptance criteria
specified?
-Are these requirements shown fully approved?

REVIEW NOTES & MINUTES (PUR) Page 1 of 70 Printed: 09/13/2023


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Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
1.5 Text Block: Material Specifications
1.5.1 What specific material(s) was assumed in the No issue
quoting process? We are currently accepting mill sheets of raw materials and testing
- Does this match what is on the print? Identify specimens.
print requirement.
- Will the material(s) selected (on drwg) meet all
the applicable performance requirements? Approved
- (Supplier) Provide supporting
data/documentation for all concerns.

1.5.2 Does the supplier know of any other, more No issue


suitable material(s) for this application? We are currently accepting mill sheets of raw materials and testing
- List all recommended materials. specimens.
- Provide "Product/Technical Data Sheets" for
Approved
each material.
- Explain why alternate material(s) is better or
equally suited.

1.6 Text Block: Finish and Appearance Requirements


1.6.1 Appearance / visual aspects (i.e. graining, No issue
burrs, corrosion, etc.): Specify the master sample, view the master sample, and visually
-If item is grained, has supplier completed the inspect it.
"MOLD GRAINING APPROVAL" TAB?
- If item has a specified color are color masters
available?
-Have boundary samples been established?
(Use similar production components until Approved
production tool items are available for use).
-Are visual standards acceptable as shown on
the "VISUAL STANDARD" tab?
-Is the "VISUAL STANDARD PROCESS FLOW"
acceptable for implementation?

1.6.2 Are there any special (non-typical) finish No issue


requirements (appearance, coating,
performance, etc.)? Approved
- List any issues with the special requirements?

1.7 Text Block: Dimensional Standards


1.7.1 Are general tolerances appropriate (achievable) No issue
for the component?
- List all exceptions (with an explanation and Approved
supporting data / documentation).

1.8 Text Block: Miscellaneous


1.8.1 Are all notes clearly understood? No issue
- Is there anything in the text block section that Approved
needs more clarification or understanding?

Section #2: Datum's, Critical Dimensions / Characteristics, and Gauges (Supplier Quality Development - SQD)
2.1 Datum's:
2.1.1 Does the supplier understand the "A" Datum as N/A
shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately? N/A
- Does the supplier agree with this datum
structure?

2.1.2 Does the supplier understand the "B" Datum as N/A


shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately?
N/A
- Does the supplier agree with this datum
structure?

2.1.3 Does the supplier understand the "C" Datum as N/A


shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately?
N/A
- Does the supplier agree with this datum
structure?

2.1.4 Does the supplier understand the "D" Datum as N/A


shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately? N/A
- Does the supplier agree with this datum
structure?

2.1.5 Does the supplier understand the "E" Datum as N/A


shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately? N/A
- Does the supplier agree with this datum
structure?

2.1.6 Does the supplier understand the "restraint of No issue


part" requirements for checking?
Can restraints be duplicated for CMM
N/A
measurement?

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Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
2.2 Functional Critical Dimensions: Must meet CpK per PPAP requirements and ongoing monitoring (See 1.1.1)
2.2.1 FUNCTIONAL CRITICAL N/A
F DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement N/A
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain.

2.2.2 FUNCTIONAL CRITICAL N/A


F DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied? N/A
- Are there any issues meeting this functional
requirement? List & explain.

2.2.3 FUNCTIONAL CRITICAL N/A


F DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied? N/A
- Are there any issues meeting this functional
requirement? List & explain.

2.2.4 FUNCTIONAL CRITICAL N/A


F DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied? N/A
- Are there any issues meeting this functional
requirement? List & explain.

2.3 Customer Critical Dimensions: Annual re-certification of customer critical characteristics required per approved control plan
2.3.1 CUSTOMER CRITICAL No issue
C DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
Approved
- Are there any issues meeting this functional
requirement? List & explain.

2.3.2 CUSTOMER CRITICAL No issue


C DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied? Approved
- Are there any issues meeting this functional
requirement? List & explain.

2.4 Inspection Points and Gauging


2.4.1 Are all inspection points clearly defined for Check fixture check No issue.
each Functional Critical, & Customer Critical,
Characteristic?
- Are there any issues with the measurement of
these points on the check fixture or CMM?
-Does supplier understand which check points
are required on the check fixture, and which are Approved
required for CMM (or other method of)
measurement? If no, Inalfa to clarify.
Has the "CHECK FIXTURE DESIGN" tab been
reviewed"
- List & explain any concerns or issues.

2.4.2 Does supplier understand measurement We have no issue.


reporting requirements per the "KEY
CHARACTERISTICS MATRIX" tab?
- If NO, Inalfa to clarify.
Supplier agrees to perform a full dimensional Approved
layout for three pieces of every item on an
annual basis. Data is to be maintained and
supplied when requested by Inalfa.

2.4.3 Gages: We have no issue.


- Will your quality gauges and check fixtures
conform to the requirements of the "CHECK
FIXTURE DESIGN" tab? Approved
- List all exceptions.
- What is suppliers alternate proposal?

2.4.4 Gage concept to be provided by supplier YEEMAK SIWOO will submit the concept drawing for gage within
2 weeks after K/O (for approval by Inalfa 2weeks after K/O.
Engineering and Supplier Quality). To Be
- Inalfa response shall be provided in 2 weeks. Decided

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Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
2.5 Item Dimensions (Review every dimension on the print and list the dimensions with issues):
Are any additional dimensions / features required to be functional to insure production process capability?
Annual certification required for each item on all print dimensions and notes based on a sample size of three pieces.
2.5.1 Dimension and Tolerance: No issue
(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

2.5.2 Dimension and Tolerance: No issue


(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

2.5.3 Dimension and Tolerance: No issue


(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

2.5.4 Dimension and Tolerance: No issue


(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

2.5.5 Dimension and Tolerance: No issue


(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

2.5.6 Dimension and Tolerance: No issue


(identify location on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
- Are there any issues meeting this functional
requirement? List & explain. Approved

Section #3: Tooling (Tooling Manager)


3.1 Tooling:
3.1.1 Tooling Manual: (per applicable manufacturing No Issue
process for component)
- Has supplier obtained and reviewed (as
applicable) Injection Mold (Plastic) Design
Manual, Doc # IRS GSQAP-006?
- Will your manufacturing tools conform to the
requirements of the applicable document?
Approved

3.1.2 Tooling Inserts N/A


-Are tooling inserts (if applicable) as shown on
the "TOOL INSERT LOCATIONS" tab?
- List all exceptions. N/A
- What is suppliers alternate proposal ?

3.1.3 Mold Flow Analysis: (per applicable No Issue ( Same concept with serial )
manufacturing process for component)
- Has supplier obtained and reviewed (as
applicable) Inalfa Mold Flow analysis worksheet
for MFA requirements
- Will your manufacturing tools conform to the Approved
MFA requirements of the applicable document?
- List all exceptions.
- What is suppliers alternate proposal ?

3.1.4 Mold Specifications: No Issue


Has the "MOLD SPECIFICATIONS" tab been
completed and approved (if applicable)? Approved

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Question Comment / Action Required
Resp. Date Status Date
3.1.5 No Issue
Mold Graining:
Has the "Mold Graining Approval Sheet" been
Approved
reviewed where applicable for customer graining
requirements.

3.1.6 Mold Steel Recommendations: No Issue


Has the "MOLD STEEL RECOMMENDATIONS"
tab been reviewed and approved (if applicable)?
-List material to be used, does this comply with Approved
the recommendation?

3.1.7 Tooling Concept: No Issue


Where will the parting lines, ejector pins, gates,
etc. be located on the item?
- Are the acceptable locations for these features
clearly identified by Inalfa?
- Are you investigated if the Inalfa design can
generate BAD STEEL CONDITION in the mold ,
as shown in "TOOLS-BEAM W MOTOR" tab? Approved
- What is your proposal to eliminate it ?
- Note: Tool die line-up/drawing and control plan
are required 3 weeks after K/O (for final approval
by Inalfa Engineering and Supplier Quality).
Inalfa response shall be provided in 2 weeks.

3.1.8 Tooling Life/ Preventative Maintanance No Issue


Supplier to review Inalfa Roof Systems tooling
lifetime and Maintenance plan document
Does the supplier have a preventative
maintenance plan for tooling and capital
equipment? Which critical features from the item
design require additional maintenance and what Approved
is the frequency for review and maintenance of
the tool? Has the maintenance plan been
approved by the Inalfa Tooling Manager?

3.1.9 Tooling Concept No Issue


- Has the supplier reviewed and provided
feedback on the Inalfa Hybrid tooling concepts
Approved

3.1.10 Component Marking: No Issue


- Is the size, location, and type of marking
properly identified on the drawing?
- How will the tooling incorporate our component
item number, changeable revision level, date
wheel and material recycling code Approved
(if required)?
- List all concerns.
- What is suppliers alternate proposal?

3.1.11 Tooling Life/ Preventative Maintance No Issue


Supplier to review Inalfa Roof Systems tooling
lifetime and Maintenance plan document
Does the supplier have a preventative
maintenance plan for tooling and capital
equipment? Which critical features from the item
design require additional maintenance and what is Approved
the frequency for review and maintenance of the
tool? Has the maintenance plan been approved by
the Inalfa Tooling Manager?

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Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
Section #4: Process - Supplier (Purchasing)
4.1 Manufacturability:
4.1.1 Has the "TIMING" plan been reviewed with the No Issue
Supplier? Are there any issues? Approved

4.1.2 Does supplier understand the function, and No Issue


assembly sequence, of the item at Inalfa? Approved

4.1.3 If the component is an assembly, are all the No Issue


components identified? Approved
- Have the supplier list the BOM.
4.1.4 Supplier to show, and team to review, quoted N/A
process flow based on similar existing items
(Process flow through mold, secondary
operations, die line-up, finishing operations,
number of cavities / dies, fastening or assembly
stages / equipment, etc.). N/A
-Has the "KEY PROCESS GUIDELINES" tab
been reviewed? Are there any concerns or
issues?
-Have all lower tier suppliers been identified?
4.1.5 Has a representative Control Plan been No Issue
reviewed? Are all Inalfa Control Plan
requirements identified and agreed upon? Approved
- Has the "KEY CHARACTERISTICS MATRIX"
tab been reviewed?

4.1.6 -Would any design changes improve the N/A


manufacturability of this item? List all.
-What are the high cost drivers of this design? N/A
- Is there a less expensive way to make this
item? List proposals and impact on design.

4.1.7 Has the visual standard and the visual standard No Issue
definition been reviewed and approved?
Approved

4.2 FMEA Reviews:


4.2.1 Where supplier is design responsible, has supplier No patent issues.
confirmed there are no patent issues with the Approved
design?

4.2.2 Review Supplier PFMEA for a similar production No Issue


item. Approved

4.3 Prototype / Production Information:


4.3.1 What kind of tools/processes will be used during N/A ( Serial tooling )
the prototype phase? Purchasing to give supplier
approximate prototype due date and approximate N/A
quantities required.

4.3.2 What kind of tools / processes will be used for N/A ( Serial tooling )
prototype items? Purchasing to give supplier 1st
dimensionally correct item due date, PPAP due
N/A
date, and SOP date. Purchasing to also provide
approximate quantities required.

4.3.3 What is the intended production location? YEEMAK SIWOO chennai plant
Approved

4.3.4 Supplier Timelines are expected on a weekly basis No Issue


(first timeline due prior to sourcing). Purchasing to
give the suppliers a location specific timeline Approved
format that we would like them to capture.

4.3.5 Does the supplier conduct and document design No Issue


reviews (similar to this process) for Inalfa specified
components or processes with their suppliers (if
applicable)? If concerns exist, supplier must review Approved
with Inalfa if potential problem with final product.

4.4 Capital Equipment:


4.4.1 Supplier to provide specific capital equipment Replace with a company introduction.
information (press size, type, age, open capacity,
manual or automatic cycle) that would be used for Approved
the program.

4.4.2 What is the planned capacity for this item (Hourly, No Issue
Weekly, Annual)? The press facility can produce 200,000 units per month. AY cars
-Has the "EQUIPMENT CAPACITY WORKSHEET" account for 20% capa.
tab been completed? Approved
-What is the planned tool life (item quantity)?
-Are there any issues?

4.4.3 Does this item require the supplier to purchase No need extra equpment
new equipment? If yes, describe. Approved

REVIEW NOTES & MINUTES (PUR) Page 6 of 70 Printed: 09/13/2023


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Person Due Approval Closed


Question Comment / Action Required
Resp. Date Status Date
Section #5: Packaging (Logistics)
5.1 Packaging:
5.1.1 What type of packaging (returnable or expendable) Needs discussion with IGGS
will be intended for this item? What is the planned
size of packaging? What is optimal quantity per
container? Has Supplier received copies of Inalfa To Be
Packaging Standards Document # IRS PS 01? Decided

5.1.2 Is existing returnable packaging planned for this Needs discussion with IGGS
item? Has a study been completed to insure
proper fit of the item? Are there adequate
quantities available to include this item? If no, is To Be
another container available or is new packaging Decided
required?

5.1.3 Supplier required to submit a backup packaging Needs discussion with IGGS
plan for use if returnable packaging is not
To Be
available. Has the backup plan been approved by
Decided
Inalfa?

5.1.4 Does supplier have concerns about shipping Needs discussion with IGGS To Be
containers or item damage in transit? Decided
5.1.5 Does the supplier understand Inalfa's approved Needs discussion with IGGS
criteria for shipping (labeling, etc)? If not, please To Be
review this on the supplier portal. Decided

5.1.6 Supplier is required to supply packaging concept at Needs discussion with IGGS
the time of submitting their final quote. Packaging
Approval Form # IRS PASO-01 to be completed
To Be
and submitted with Quote.
Decided
-Has the "PACKAGING" tab been reviewed?
-Are there any issues?

Section #6: Miscellaneous Issues (Purchasing)


6.1 Service Agreement:
6.1.1 Has purchasing set up a service agreement? Needs discussion with IGGS
Clarify service requirements to the supplier.
Supplier must supply service items for 15 years
after the end of production. The first 3 years of
service items will be at the current production piece To Be
price. Decided
If Engineering Change, review service
requirements for previous design.

6.2 Summary:
6.2.1 Summarize the meeting, review open actions. Approved

ADD A NEW TAB OR FORM FOR ENGINEERING CHANGES

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TIMING PLAN

Timeline Start Date


11-Aug-23
Calendar Week 8/7~138/14~20
8/21~27
8/28~9/29/3~109/11~17
9/18~249/25~110/2~8
32 Month
Number Requirement 9/13/2023 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 Design Review '23.7.27~'23.8.09

2 ECO Release '23.8.07~'23.8.09

3 Tooling Kick Off (Release) '23.8.10

4 Mould flow analysis complete '23.8.11~'23.8.18

5 Tool design '23.8.11~'23.8.18

Review by Inalfa and formal "Go in steel" - Tooling


6
Specialist - Milestone

7 Milling start '23.8.21~'23.9.22

8 Milling end / assembly of the tool '23.9.25~'23.9.29

9 Checking fixture (concept/realization and validation) N/A

10 PL1 Shots (AP1) '23.10.02~'23.10.06

Visit at the supplier (SQD and Tooling specialist) -


11
Milestone

12 PL2 Shots (SP1) '24.4.01~'24.4.05

Visit at the supplier (SQD and Tooling specialist) -


13
Milestone

14 Dimensional results with SCAP '24.4.08~'24.4.10

15 Material functional testing '24.4.22~24.5.30

16 Graining (to be authorized by SQD Inalfa) N/A

17 IMDS '24.3.25~'24.3.29

18 Full PPAP submission '24.9.01~'24.9.20

19 R@R and delivery to Inalfa - Milestone '24.11.01~'24.11.30

N/A 7-Mar-11 Number 6 corrected to Parts with Dimensions Received J. Rose


N/A 1-Mar-11 Modified date formula, desc. for Parts with Dimensionswas interim PPAP J. Rose
N/A 28-Feb-11 Released latest format J. Rose
ENG. CHANGE REVISION APPROVED
DESCRIPTION OF CHANGE
NUMBER DATE BY

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TEST REQUIREMENTS
Plastic Parts

Select Part for Kick-Off Review


(Tests not required will be in grey)

Fill in by Supplier
Specification / Test
Paragraph
Item (A,B,C etc) Test Method Acceptance Criteria
Description of test

FMVSS 302 (MS300-08); FLAMMABILITY of INTERIOR MATERIALS (in occupant compartments of motor vehicles)
Burn Resistance of Interior
- -
Components

IES50.016
CLIMATE CYCLES FOR
TEST PERFORMED
OVERMOULDED STEEL -
INALFA
PARTS

IES60.017
COATINGS FOR METAL
- Min. 240h
PARTS

MS201-01
MARKING OF MATERIALS
C
C - -
FOR AUTOMOTIV PARTS

MS201-02
PROHIBITION AND
C
C REPORTING THE USE OF
- -
HARMFUL SUBSTANCES
PARTS AND MATERIAL

MS300-55
TEST METHOD FOR THE
DETERMINATION OF THE
- -
C EMISSION OF VOCs FROM
VEHICLE PART

MS124-07
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HIGH CARBON STEEL WIRE


C RODS LOW CARBON STEEL - Min. 96h
WIRE RODS

PROGRAM SPECIFIC REQUIREMENTS


1
2
3
4
5

Specific program requirements must be added for each new kick-off review

10-Jan-14 General update


n 1-Oct-13 Added IES 60.020 requirements per latest CQD re
NA 12/9/11 Corrosion requirement aligned with Drive tube CQ
N/A 8/11/2011 Combined separate commodity test tabs to one fil
ENG. CHANGE NUMBER REVISION
Public #_x000D_

T REQUIREMENTS
STATUS
Plastic Parts
OVERVIEW:
Approved
Kick-Off Review Drive Cable GLASS Not Approved - Major
red will be in grey) Not Approved - Minor
To Be Decided
N/A
Fill in by Supplier

Test Qty. & Freq.


Test Equipment A: Prototype Commitment for
Required B: Initial PPAP Reason for Non-Compliance
C: Annual Cert. Compliance
Available (Y/N?)
D: Ongoing Prod.

nts of motor vehicles)

Y A Yes

N/A A Yes

Y A Yes

N/A A Yes

N/A A Yes

Y A Yes
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Y A Yes

equirements per latest CQD releases


ent aligned with Drive tube CQD (240 hrs. was 408 hrs.)
commodity test tabs to one file
DESCRIPTION OF CHANGE
Public #_x000D_

Test Specifications
Summary

1
0
0
0
0
Fill in by I.R.S. only Set column K to N/A for all greyed out lines

Decision by
Alternate Proposal Remark
IRS

실내 부품
Approved
내화성

Approved

Approved

Approved

Approved

Approved
Public #_x000D_

Approved

AM
J. Rose
EP
J. Rose
APPROVED BY
Public #_x000D_

Drive Cable GLASS


Beam Without Drive Tubes
Drain Channel
Drain Piece - Rear
Relief Tube
Sunshade Stop
K to N/A for all greyed out lines
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EQUIPMENT CAPACITY PLAN


(See bottom for Instructions and Supplier : Completed By: Phone #: Updated on:

Example)
Project : Name AY1 YEEMAK SIWOO JONGCHAN OH 010-8533-1293 11-Aug-23

Part Number Part Name

50015349/50015350 ASSY DRIVE CABLE GLASS LH/RH


Component 1 Supplier to complete all YELLOW areas
50015361/50015362 ASSY DRIVE CABLE ROLLO LH/RH
Automatically calculated field,
Tooling Description
do not input any data! SECTION 1 : VOLUME DESCRIPTION

INALFA TAKT TIME :

G = Efficiency of process ( all inclusive,

per
(seconds)

PROCESS CAPACITY
ASSUMPTIONS :

CT = CYCLE TIME in sec.


TT = TAKT TIME in sec.

Volumes of Roofs

Volumes of Roofs

Volumes of Roofs
H = Main equipment availability
A = Weeks per YEAR (max. 48)

for CARRY OVER

for CARRY OVER


for New project
T = Number of tools available

Total Volumes
- 48 weeks per year

B = Days per WEEK (max 6)

E = Parts per process cycle

always > 1

project X

project Y
- 5 days per week

YEARS

of parts
WK

TT/CT =
Requested volume Working week Requested Volume - 8 hours per shift

D = Number of SHIFT
- 2 shifts per day

C = Hours per SHIFT

F = 1 / Parts per roof


ROOFS/year (according to Parts / Week
- 85% process efficiency
Inalfa assumptions)
Max value allowed
- 1 tool available
- Equipment availability =

max 85% )

week (%)
100%

PRODUCTION DATA YEAR 1


NOMINAL
Volume

408.0
48,600 48 1,013 241.8 48 6 7.5 3 1 1 85% 100% 1 11 37.09 48600 48600
2025
Peak 1
10% Increase over

370.9
Nominal 53,460 48 1,114 219.8 48 6 7.5 3 1 1 85% 100% 1 11 33.72 54000 54000
2026
Peak 2
25 % Increase over

326.4
Nominal 60,750 48 1,266 193.4 48 6 7.5 3 1 1 85% 100% 1 11 29.67 56700 56700
2027

59400 59400
2028

59400 59400
PRODUCTION DATA YEAR 2 2029
NOMINAL Volume

367.2
54,000 48 1,125 217.6 48 6 7.5 3 1 1 85% 100% 1 11 33.38 40500 40500
2030
Peak 1

333.8
10% Increased of Nominal
59,400 48 1,238 197.8 48 6 7.5 3 1 1 85% 100% 1 11 30.35 0
2031
Peak 2

293.8
25 % Increased of Nominal
67,500 48 1,406 174.1 48 6 7.5 3 1 1 85% 100% 1 11 26.71 0
2032

0
2033

PRODUCTION DATA YEAR 3 0


2034
NOMINAL Volume

349.7
56,700 48 1,181 207.2 48 6 7.5 3 1 1 85% 100% 1 11 31.79 0
2035
Peak 1

317.9
10% Increase over
Nominal
62,370 48 1,299 188.4 48 6 7.5 3 1 1 85% 100% 1 11 28.90 0
2036
Peak 2
279.8

25 % Increase over
Nominal
70,875 48 1,477 165.8 48 6 7.5 3 1 1 85% 100% 1 11 25.43

PRODUCTION DATA YEAR 4


NOMINAL Volume
59,400 48 1,238 198 48 6 7.5 3 1 1 85% 100% 1 11 30.35
333.8

Peak 1
10% Increase over
65,340 48 1,361 180 48 6 7.5 3 1 1 85% 100% 1 11 27.59
303.5

Nominal

Peak 2
25 % Increase over
74,250 48 1,547 158 48 6 7.5 3 1 1 85% 100% 1 11 24.28
267.1

Nominal

PRODUCTION DATA WITH IMPROVED SCENARIO AFTER INVESTMENTS

NOMINAL Volume 59,400 48 1,238 198 48 6 7.5 3 1 1 85% 100% 1 11 30.35


333.8

Peak 1
10% Increase over
65,340 48 1,361 180 48 6 7.5 3 1 1 85% 100% 1 11 27.59
303.5

Nominal

Peak 2
25 % Increase over
74,250 48 1,547 158 48 6 7.5 3 1 1 85% 100% 1 11 24.28
267.1

Nominal

IMPROVED PROCESS DESCRIPTION

Bottle Neck
Operations Description Equipment
Y/N

10 Strand SUNROOF STRANDING M/C NO

20 Coiling (Heating) COILING WIRE REWINDER NO

30 Flocking Winding (Glue Dry) COATING TYPE FLOCKING M/C NO

40 Wire cutting SUNROOF CUTTING M/C NO

50 Chamfer of end of wire CHAMFER OF END OF WIRE M/C NO

60 Stripping STRIPPING M/C NO

70 NIPPLE END Extrusion Injection molding M/C NO

80 HOLDER Extrusion Injection molding M/C NO

90 End of line test

100 Packing, Stack

INVESTMENTS Needed I L M N O P
Direct OR Sub-

#
Actions to improve process :
Description of tools / equipment
Estimate /
Fix Cost
supplier

Investment Costs Name of Sub- Lead time (Max 30 % Investment rate


in US $ supplier weeks) dedicated to this program
1
2
3
4
5
6
7
8
9

TOTAL : $0 0 #DIV/0!
Public # _x0 0 0D_

LEGEND

ITEM PARAMETERS VALUE Note


A Working weeks per year Must consider 48
B Days per week Can be considered 5 or 6
C Hours per shifts Must be consider 8
Can be applied 1 , 2 , 3 , according to the volume requested. Maximum allowed
D Number of shift
production hours per week = 6 days x 24 hours = 144 hours
It is the N° of parts produced every time by the main tool or equipment = N° of tool's
E Parts per process cycle cavity if the tool produce only 1 part ( NO LH/RH ) . If producing 1 part then E = 1 . If
the tool produce 1 LH and 1 RH parts then E =1

F Opposite value of the N° of parts needed in a roof . ( Example If there are 2 parts
1 / parts per roof
every roof then F = 0,5 )

G Efficiency of the process Best utilization of the process time , including all efficiency factors. Max. accepted value
is 0.85 or 85%
Availability of the production machine for this project . ( Example : for an injection
H Equipment availability press , if that is dedicated at this project then H = 1 , if the press is only 50% available
for this project then H = 0.5 or 50%
Minimum value available to be able to produce requested volume , with the
TT Takt Time
production conditions settled
Measured time needed to produce 1 component , including the packaging time . CT
CT Cycle Time
must be measured during R&B . CT must be always smaller then the TT
Factor to recognize if the process is able to produce the requested volume . Must be
TT/CT Process ability
always > 1
Investment required to produce requested volume . Must indicate value for every
I Investment
modification , new tool or equipment to added .
Indicates if the investment is done directly by the Inalfa's supplier or by another
L Direct / Sub-supplier company ( sub-supplier ) that supply some components needed to produce the part
to the Inalfa's supplier . Indicate D or S
M Sub-supplier It indicate the name of the external company
N Lead time It indicate the lead time to start produce new volume including training , prepare new l
O Estimate / Fix It indicate if the value of the investments is an estimation or a fixed price
Factor to indicate if the investment is done only for the project shown or can be used
P % investments for this program
also for other projects.
Available tooling to produce component in subject . Generally it is 1 , but for high
volume production can be 2 or more , depending on cycle time . If this number is
T Number of Tooling Available
more than 1 , need to recalculate H value ( Equipment availability ) considering the
overall average of the availability of all Production machine

INSTRUCTIONS
- Please fill out one entire worksheet for each individual component supplied to Inalfa. If the components have a LH and RH hand, it must be indicated at the top of the format.
- Each worksheet must be completely filled out by supplier in all YELLOW cells. The GREY cells do not have to be filled , because there are in automatic formula.
-There are two requested volume assumptions to be reviewed : Nominal Production and Peak production. Buyer will provide to you volumes in SECTION 1 and value for Peaks .
- To complete the form the actions are as follows;
1) Complete the section entitled "PRODUCTION VOLUME" by filling the yellow cells with the current actual planned process parameters for production. The goal in this section is that your current planned process will cover the NORMAL and
PEAKS requested volumes. In this phase is very important to define correctly the CYCLE TIME. (The cycle time must be EVALUATED based on your quotation). If your current planned process parameters ( A , B , C , .. ) are correct, the value of
TT/CT Must be > 1, and the TT/CT column cells will change to GREEN. If the parameters are incorrect, or do not meet the requested volume, the cells will change to GREY.
- If is not possible to cover whole requested volumes with the current planned process parameters, please define a potential action plane to achieve the goals. Based on these actions, move to the next section and complete.
2) Complete the section entitled "IMPROVED SCENARIO" with the new potential process parameters based on your actions noted above, and verify if the problems are solved.
3) Once the parameters are correct, and the CT/TT column cells are green, start fill the three sections entitled "INVESTMENTS". In the "description tool / equipment" rows note the tools and equipment which is already in place (based on your TCAR)
and used for the forecasted production. In this case, the costs cells only need to be filled if modifications to the existing equipment or tools is necessary. Once if you have listed all current tooling in use, IF REQUIRED, specifically list potential new
tools, equipment, gages, fixtures, etc. which may be needed to cover the related volume. For these items, supplier must indicate the estimated investments and the estimated complete lead time. Supplier have to indicate also if the investment will be
100% dedicated to the program in subject or if will be used also for other programs ( INVESTMENT RATE ) . Lead time should including all necessary work and time spent for each action needed, before to start producing at a new volume (i.e.: pkg,
hire and train of extra shift, material order lead time, ect.
4) In the section entitled "LEGEND" provide a short explanation about the potential actions forecasted above. Provide this description in the appropriate row, in the open cells in the column "explanation". An explanation only needs to be provided in
those cells where there have been changed parameters in order to achieve the requested volumes.

NOTE: PLEASE REVIEW THE SAMPLE WORKSHEETS PROVIDED FOR FURTHER CLARIFICATION ON HOW TO FILL THE FORMS.

NOTE: WHEN EVER YOU SEE A "LETTER" NOTED WITHIN THE FORM, PLEASE REFER TO THE LEGEND SECTION FOR ACTUAL DEFINITIONS AND DESCRIPTIONS.

NOTE:
THE COMPLETED WORKSHEETS MUST BE SUBMITTED TO INALFA BEFORE FIRST KICK-OFF REVIEW

EXAMPLE
EQUIPMENT CAPACITY PLAN
(See bottom for Instructions and Supplier : Completed By: Phone #: Updated on:

Example)
Project : Name Inalfa F. Bonucci 248 371 0901 13-Sep-12
E70
Part Number Part Name

Component 1 Supplier to complete all YELLOW areas


12345678 Reinforcement RH
Automatically calculated field,
Tooling Description
do not input any data!

INALFA TAKT TIME :


G = Efficiency of process ( all inclusive,

per

(seconds)
PROCESS CAPACITY

ASSUMPTIONS :
CT = CYCLE TIME in sec.
TT = TAKT TIME in sec.
H = Main equipment availability
A = Weeks per YEAR (max. 48)

T = Number of tools available

- 48 weeks per year


B = Days per WEEK (max 6)

E = Parts per process cycle

always > 1

- 5 days per week


TT/CT =

WK
Requested volume Working week Requested Volume - 8 hours per shift
D = Number of SHIFT

- 2 shifts per day


C = Hours per SHIFT

F = 1 / Parts per roof

ROOFS/year (according to Parts / Week


- 85% process efficiency
Inalfa assumptions)
Max value allowed
- 1 tool available
- Equipment availability =
max 85% )

week (%)

100%

PRODUCTION DATA YEAR 1


NOMINAL
Volume
106.8

110,000 48 2,292 106.8 48 5 8 2 1 1 85% 100% 1 100 1.07

Peak 1
10% Increase over
97.1

Nominal 121,000 48 2,521 97.1 48 5 8 2 1 1 85% 100% 1 100 0.97

Peak 2
25 % Increase over
85.5

Nominal 137,500 48 2,865 85.5 48 5 8 2 1 1 85% 100% 1 100 0.85

PRODUCTION DATA WITH IMPROVED SCENARIO AFTER INVESTMENTS

NOMINAL Volume 110,000 48 2,292 107 48 5 8 2 1 1 85% 100% 1 100 1.07


106.8

Peak 1
10% Increase over
121,000 48 2,521 97 48 5 8 3 1 1 85% 100% 1 100 1.46
145.7

Nominal

Peak 2
25 % Increase over
137,500 48 2,865 85 48 5 8 3 1 1 85% 100% 1 100 1.28
128.2

Nominal
Public

PACKAGING SPECIFICATION DATA SHEET


#

PART INFORMATION (Digital Photo or Sketch) INTERIOR DESIGN DIGITAL PHOTO (or Sketch) PROGRAM: REVISION NO.
AY1
PLANT(s):
DDS DIMENSIONS TARE
QTY CNTR NAME MATERIALS L W H WT
1600/pallet BOX Container Carton 1100 980 750 271

DIMENSIONS (IN) WEIGHT PER


L W H PIECE (Kg) 100pcs cable+ 1Box
530 470 175 16 No physical object,
predicted weight
CONTAINER PHOTO (or Sketch)

PACKAGING NOTES INALFA CNTR PCS / WEIGHT/CONTAINER


No. Layers Parts Per Layer CNTR I.D. WEIGHT CNTR PART GROSS
PRIMARY 16Kg/pallet
4 400 CONTAINER one pallet=16
Box(100pcs/Box)
UNIT
LOAD 1600pcs
INALFA PART NUMBERS: PACKAGING APPROVAL TRANSPORTATION SHIPPING INTERVAL
1.) 55015361 INALFA USE ONLY TYPE
2.)55015362 Inalfa Truck Daily ✘
CONTAINER TYPE 3.)
✘ INALFA STANDARD Returnable Container 4.) M.E. Approval: Date: Milk Run Every Other Day
UNIQUE Returnable Container 5.) June.Part
✘ EXPENDABLE Container Commercial Direct Twice Per week
SHIPPING UNIT PHOTO (or Sketch) PART NAME: Materials Approval: Date:
ASSY DRIVE CABLE GALSS Sungsu.Kwon Commercial Indirect Weekly
SUPPLIER NAME:
DDS Manufacturing Approval: Date: International-Land Bi-Weekly
INALFA SUPPLIER CODE: Hansik.Park
International-Air Monthly
SUPPLIER ADDRESS: SDE Approval: Date:
Hansoo.lee International-Sea Other

International- Rail
PHONE: SUPPLIER APPROVAL

FAX:
CONTACT:
TITLE: Supplier Approval: Date:
CONTAINERS PER PALLET EMAIL:
MIN: 1 MAX: 1 DATE:
REMARK 1: REMEMBER, THE RESPONSIBILITY FOR ENSURING COMPONENT QUALITY FROM YOUR PLANT TO THE POINT OF USE REMAINS WITH YOU - THE SUPPLIER OF THE PRODUCT.
REMARK 2: ALL NEW CONTAINERS MUST BE LABELED ACCORDING TO CURRENT INALFA PACKAGING GUIDELINES!

Date Issued: April 2001.


/691078473.xlsx/PACKAGING FORM Page 19 of 70
Date Revised: June 10, 2002.
Public #_x000D_

Inalfa Roof Systems


Injection Molding Tooling Specifications Form - Doc.# IRS MDB-STBD-02 (Sht 1)

A. SPECIFIC BUILD DATA - MOLD FOR PLASTIC PARTS - Tool TAG #


(Check Boxes as appropriate)

Toolmaker : Insourcing Tool Maker Name and Country:


Outsourcing (Add Names) Tool Maker Name and Country:

Did you already worked with this Toolmaker ?


If NO , explain why you want to use this new Toolmaker

Is the Toolmaker an Inalfa Preferred Toolmaker ?


Who is responsible for Tooling design ?
Who is responsible for Gauges design ?

Mold Type: Conventional Three-Plate Hot Runner Hybrid

Other List:

Number of Cavities:

Inserts: Cavity Qty: Core Qty: Motor area

Holes Qty: Other Specify areas and Qty :

Movements: Sliders Qty: Lifter Qty: Mechanical

Ejector System: Standard Reverse Other Describe:

Movement : Tapping Press devices Using independent Hydraulic System

Direct on tool
Injection System: Hot Runner / Manifold Cold Runner
On an insert

In the cavity In the core Gas assistant system

Drop Valve

Gate Type: Edge Submarine Hot Tip

Other Gate Size (dia. OR wxh):


Describe : Gate Location : For PU Must be indicated in which sid

Is the planned type of gate easily changeable if necessary? Describe:

Runner Type: Full Round Half Round Hot Trapezoidal


Public #_x000D_

Manifold Supplier : Hot drop Supplier:

Cavity Steel: S-7 / 1.2357 H-11 / 1.2343 P-20 / 1.2378


(AISI / W.NR)
Final Steel Hardness (HRC):

Surface Treatment: Nitrogen Dyna blu Local Hardening

Other (Specify):

Core Steel: S-7 / 1.2357 H-11 / 1.2343 P-20 / 1.2378


(AISI / W.NR)
Final Steel Hardness (HRC):

Surface Treatment: Nitrogen Dyna blu Local Hardening

Other (Specify):

Sliders / Lifters: S-7 / 1.2357 H-11 / 1.2343 P-20 / 1.2378


(AISI / W.NR)
Final Steel Hardness (HRC):

Surface Treatment: Nitrogen Dyna blu Local Hardening

Other (Specify):

Tool Dimensions: Maximum Dimensions: Width (mm): Height (mm):

Sprue: Puller: Radius:

Venting: Cavity: Width (mm): Depth (mm):

Core: Width (mm): Depth (mm):

Runner: Width (mm): Depth (mm):

Polishing / Finish: Cavity (Ra): Core (Ra):

Draft Angle: General: 1 Degree Recommended for Graining (Deg.): Min.

Process
Mold Flow Analysis Forecasted NOT Forecasted

Knockout Pattern: Cavity: Core:

Press: Type: Horizontal Vertical

Size (Tonnage): P1 = Plastic Material Max Weight Capacity (Kg):


Specify if US or ISO Tons
Public #_x000D_

P2 = Component Weight (Kg):

Plastic Material: Type / Grade: Source:

Need to Dry the material Before Molding ? YES NO Drier Temperature :

Shrinkage: Direction of Flow (%): Traverse to Flow (%):

Cycle Time: Expected Cycle Time (Seconds / Shot): Only Moulding

Normal SEE CAPACITY INFORMATION WORKSHEET

Volumes

Peak

See “Marked Print” for parting line locations, gate locations, ejector pin locations and cavity ID locations
identified and approved at initial design review meeting. Any deviation from approved print requires approv
Systems.

Inalfa Roof Systems


Injection Molding Tooling Specifications Form - Doc.# IRS MDB-STBD-02 (Sht 2)

B. ADDITIONAL SPECIFIC REQUIREMENTS for MOLD and EQUIPM


(Check One)
ADDITIONAL SPECIFIC REQUIREMENTS: Below None

TEXTURING/ GRAINING, PLATING,


COATINGS INFORMATION: (Check One)
( Check. One ) Below None
( Show specific requirements below ) Doc.# IRS SQ GA-01 Mold Graining Approval Work Sheet required

ADDITIONAL REQUIREMENTS NOT (Check One)


QUOTED: Below None
Public #_x000D_
Public #_x000D_

m- Doc.# IRS MDB-STBD-02 (Sht 1)

IC PARTS - Tool TAG # : ……….


ate)

YES NO

YES NO
Supplier Toolmaker
Supplier Toolmaker

Solid Shuttle

Qty: Injection Qty:

Qty: Hydraulic Qty:

Using Mechanical System

How many Injection points :

In:
Gas points (Qty)
Out:

Fan Sprue gate

For PU Must be indicated in which side of the glass it is forecasted

Other (Describe):
Public #_x000D_

Hot drop Supplier:

Other (Specify):

Chrome plate

Other (Specify):

Chrome plate

Other (Specify):

Chrome plate

Depth (mm):

Max.

P1/P2 = #VALUE! ( Must be < 5 )


Public #_x000D_

Drier Temperature : Drier Time :

Including secondary operations

and cavity ID locations


roved print requires approval in writing by Inalfa Roof

- Doc.# IRS MDB-STBD-02 (Sht 2)

for MOLD and EQUIPMENT

See Graining Approval Worksheet


Public #_x000D_
Public #_x000D_

Tooling Development Procedure :


Activity Responsible

1) Frozen 3D-CAD-model IRS-Engineering

2) Moldflow Analysis Supplier

3) Tooling Concept Supplier

4) Determine Compensation Strategy to


use Supplier

5) Apply Compensation Strategy (correct


Supplier
the 3D-CAD-model)

6) Basic Tooling Design ; tooling principles


Supplier
to use :

7) Final Tooling Design Supplier

8) Steel Cutting Release IRS-Tooling

9) Detailed Tooling Planning When


Supplier
timing is critical weekly updates
Public #_x000D_

10) Tooling Planning – When timing is


Toolmaker
critical weekly updates
Public #_x000D_

Applicable Documents Copy to Inalfa Remarks


CATIA-file : Inalfa to provide Frozen 3D
NO CAD model to supplier for
……… rev. … DMU : ….. tooling development
Supplier to perform and
Moldflow Communicator Format + pdf-
YES supply results of MFA analysis
file
to Inalfa
Supplier to provide hybrid
tooling concept to identify
Production tooling concept Yes insert locations and quantity
for both core and cavity

PPT-file showing :
Supplier to provide a mold
-shrinkage applied X,Y,Z YES compensation strategy within
3 weeks of purchasing KO
-warpage correction X,Y,Z (position)

Supplier to provide 3D CAD


Corrected part file (CATIA) used in CAD- data (STP format) to Inalfa of
YES
design tool the compensation strategy
applied to the mold

Supplier to fill out in KOR


Inalfa Tooling Specification Sheet (see document the mold
YES
KOR-document) specification document prior
to purchasing KO

Supplier to provide to Inalfa


Native 3D-CAD or STEP-format of the 3D CAD model (STP
YES
complete tool format) of the production
intent injection mold tool

NOTE : Inalfa steel cutting


release is not a relief of
Steel Cutting Release Inalfa NO supplier responsibility for
tooling shot life and tooling
functioning

Planning on tooling part level


with all consecutive steps of
To be agreed YES manufacturing ; buy steel
– milling – drilling – hardening
– electrodes etc.
Public #_x000D_

Inalfa will define some major


tooling parts for which IRS will
receive an update photograph
To be agreed YES to show the progress (the
tooling part may be
photographed even onto the
manufacturing machine)
Public #_x000D_

Completion Date
Public #_x000D_
Public #_x000D_

Visual Standard Example of mark not in


Plastic Parts
Zone Location

K
Defect Type / Definition Photo/Description
Zone “A” Zone “B” Zone “C”

Marks not in colour

Sink marks
NOT Only 1 max
Acceptable 1mm x 1mm

NOT
Acceptable
NOT
Acceptable

Acceptable
Acceptable
NO
NOT NOT
Silvering Acceptable
Acceptable Acceptable

Acceptable Example of bur or bad


No
NOT NOT
Burrs / Gate of injection Interference
Acceptable Acceptable
with other
parts

NOT NOT NOT


Short shots Missing Material
Acceptable Acceptable Acceptable

Acceptable -
NOT To be
Glass fiber Acceptable
Acceptable agreed with
SQD

Zone Definition
Zone A - Moderate to high visibility to vehicle
occupants
Zone B - Moderate to low visibility to vehicle
occupants
Zone C - Low to no visibility to vehicle occupants

Correct Viewing
Directions
Public #_x000D_

Light
Sourc
e

600 MM
( Approximate
Arms Length)

45
Degr
ees

Candles (1076 lux) or greater. Item


should be held at 45 degrees to the
light source and viewed at
approximately a 90 degree angle to
the surface being inspected at a
distance of approximately 600 mm
Public #_x000D_

16- Oct-
General Revision AM
11
Added template to
5-May-11 J. Rose
file
ENG.
REVISIO DESCRIPTION OF APPROV
CHANGE
N DATE CHANGE ED BY
NUMBER
Public #_x000D_

Example of mark not in colour Example of sink mark

NO K
NO K
Example of Silvering (bad
Example of bur or bad injection cutting conditioning of the material)

NO K K
NO
IMPORTANT INFO

The zones have to be defined


on DWG or stated on a similar
sample (signed by both
parties) before the kick off.

NOOKK
N
Example of glass fiber on the
surface (bad flow or bad tool
temperature)
NOOKK
N
Public
Example of glass fiber on the
#_x000D_

surface (bad flow or bad tool


temperature)

NO K
Public #_x000D_

NO K
bad
aterial)

OK

ple of glass fiber on the


e (bad flow or bad tool
erature)
Public
ple of glass fiber on the
#_x000D_

e (bad flow or bad tool


erature)

Example of glass fiber on the


surface (bad flow or bad tool
temperature)
Public #_x000D_

Visual Standard Definiti

Phase Action
A similar part in production is defined as Master
Sample => all the esthetical areas are defined and
the part is signed by SQD - ENG - Supplier.
KOR
Pictures of the component are taken and will be
part of this document;
The physical part is given to the supplier;

A component is chosen as Master Sample => all


Pre-serial the esthetical areas are defined; the part is signed
by the SQD and the Supplier.
A component is chosen as Master Sample => all
PPAP/R@R the esthetical areas are defined; the part is signed
by the SQD and the Supplier.
Public #_x000D_

d Definition

Responsability

SQD & Supplier

SQD & Supplier

SQD & Supplier


Public #_x000D_

Key Process Guid


Plastic beams with welde

Step # Process

Procurement of raw material


1

2 Receiving inspection: raw material

3 Drying the raw material

4 Verify humidity of granulate

5 Start up of injection molding process

6 Injection molding of the parts

Take out the beam and the coverplates of the injection


7 molding tool and remove the injection sprue
(If applicable)

8 Check the weight of the finished part

Inspect the parts for defects: part not completely filled,


9 deformed, burn marks, etc.

Weld the coverplates on the beams, after welding the


part should be checked if all clips are clipped in
10
completely and the coverplates are touching the beam
on the complete surface
Public #_x000D_

Weld the coverplates on the beams, after welding the


10 part should be checked if all clips are clipped in
completely and the coverplates are touching the beam
on the complete surface

Carry out the inline measurements according control


11 plan

12 If deviations from the specification are detected, the


reaction plan should be put in place immediately

"First off release procedure" should be in place and


13 used to release the production batch

14 Place the beams in the packaging

15 Labels and other necessary documentation to be


added to the packaging.

16 Ship the filled packaging to the ware house


(Shipment department)

N/A 7-Dec-12 Update carried out by K.Graafland


ENG. CHANGE
REVISION DATE DESCRIP
NUMBER
Public #_x000D_

Process Guidelines
ms with welded coverplates
Included in Process?
Comments (Supplier to complete
using drop list)

Raw material as mentioned on the released


No
Inalfa drawing

Check if the required certificates are available, link the


batch of material to a production order to secure the No
traceability

Time and temperature according supplier specification No

No

Check if the applicable documentation is available on


the work station like work instructions, control plan, No
process flow and order details

According the frozen parameter settings No

If flashes occur on locations where it is not allowed,


No
they should be removed and tool submitted for repair

No

According agreed master samples/Drawing


No
specifications

The strength of the welding should be tested


according the control plan
(Frequency and method should also be mentioned
No
also in the test tab of the KOR document)
Equipment should be "fool proof": only OK welded
assemblies can be released from the machine
Public #_x000D_

The strength of the welding should be tested


according the control plan
(Frequency and method should also be mentioned
No
also in the test tab of the KOR document)
Equipment should be "fool proof": only OK welded
assemblies can be released from the machine

Store the found measurement results in the SPC


No
system

Corrective actions to be introduced. All parts in the


production line, ware house and shipment area should
be blocked until all corrective actions have been No
carried out and parts have been sorted on the found
deviation.

Quality department should make sure that release


procedure has been followed and the production batch No
can be released

No

No

No

carried out by K.Graafland A.Mignoni


DESCRIPTION OF CHANGE APPROVED BY
Public #_x000D_

Key Proc
Plastic beams

Step # Process

1 Procurement of raw material

2 Receiving inspection: raw material

3 Drying the raw material

4 Verify humidity of granulate

5 Start up of injection molding process

Check the fit of the tubes in the injection molding tool:


6 parts to be put in and close the tool, open it again
without injection of plastic to check the parts on dents
and damages.

7 Injection molding of the parts

8 Take out the part of the injection molding tool and


remove the injection sprue

9 Check the weight of the finished part

10 Inspect the parts for defects: part not completely filled,


deformed, damaged tubes, etc.
Public #_x000D_

Carry out the inline measurements according control


11 plan, beam should be at least 2 hours out of injection
molding tool.

12 If deviations from the specification are detected, the


reaction plan should be put in place immediately

13 "First off release procedure" should be in place and


used to release the production batch

14 Place the beams in the packaging

15 Labels and other necessary documentation to be


added to the packaging

Ship the filled packaging to the ware house


16
(Shipment department)

N/A 7-Dec-12 Update carried out by K.Graaflan


ENG. CHANGE
REVISION DATE DESC
NUMBER
Public #_x000D_

Key Process Guidelines


stic beams with steel drive tubes

Included in Process?
Comments (Supplier to complete
using drop list)

Raw material as mentioned on the released


No
Inalfa drawing

Check if the required certificates are available, link the


batch of material to a production order to secure the No
traceability

Time and temperature according supplier specification No

No

Check if the applicable documentation is available on


the work station like work instructions, control plan, No
process flow and order details

By checking the tubes in the injection molding tool,


before and after the molding of the production batch, No
the risk of damaged drive tubes is smaller.

According the frozen parameter settings No

If flashes occur on locations where it is not allowed,


No
they should be remove and tool submitted for repair

No

According agreed master sample/Drawing


No
requirements
Public #_x000D_

Store the found measurement results in the SPC


No
system

Corrective actions to be introduced. All parts in the


production line, ware house and shipment area should
be blocked until all corrective actions have been No
carried out and parts have been sorted on the found
deviation.

Quality department should make sure that release


procedure has been followed and the production batch No
can be released

No

No

No

carried out by K.Graafland A.Mignoni


DESCRIPTION OF CHANGE APPROVED BY
Public #_x000D_

Key Proce
Plas

Step # Process

1 Procurement of raw material

2 Receiving inspection: raw material

3 Drying the raw material

4 Verify humidity of granulate

5 Start up of injection moulding process

6 Injection moulding of the parts

7 Take out the part of the injection moulding tool and


remove the injection sprue

8 Check the weight of the finished part


Public #_x000D_

9 Inspect the parts for defects: part not completely filled,


deformed, damaged tubes, etc

Carry out the inline measurements according


10 controlplan, beam should be at least 2 hours out of
injection moulding tool.

11

If deviations from the specification are detected, the


12 reaction plan should be put in place immediately

13 "First off release procedure" should be in place and


used to release the production batch

14 Place the beams in the packaging

15 Lables and other necessary documentation to be


added to the packaging

Ship the filled packaging to te ware house


16
(Shipment department)

N/A 7-Dec-12 Update carried out by K.Graafland


ENG. CHANGE
REVISION DATE DESCRIP
NUMBER
Public #_x000D_

Key Process Guidelines


Plastic parts

Included in Process?
Comments (Supplier to complete
using drop list)

Raw material as mentioned on the released


No
Inalfa drawing

Check if the required certificates are available, link the


batch of material to a production order to secure the No
traceability

Time and temperature according supplier specification No

No

Check if the applicable documentation is available on


the work station like work instructions, control plan, No
process flow and order details

According the frozen parameter settings No

If flashes occur on locations where it is not allowed,


No
they should be remove and tool submitted for repair

According agreed master sample and dwg. No


Public #_x000D_

According agreed master sample/Drawing


No
requirements

Store the found measurement results in the SPC


No
system

No

Corrective actions to be introduced. All parts in the


production line, ware house and shipment area should
be blocked until all corrective actions have been No
carried out and parts have been sorted on the found
deviation.

Quality department should make sure that release


procedure has been followed and the production batch No
can be released

No

No

No

carried out by K.Graafland A.Mignoni


DESCRIPTION OF CHANGE APPROVED BY
Public #_x000D_

Key Process Guid


Steel tubes for plasti

Step # Process

1 Procurement of raw material

2 Receiving inspection: straight tubes (1)

3 Receiving inspection: straight tubes (2)

4 Receiving inspection bended tubes

5 Bending of the straight tubes to the required 3D shape

100% check of the 3D shape and the presence of


6 impressions, damages and burss of the bended tubes
to be carried out.

7 Use internal packaging for the bended tubes

Transport the parts to the injection moulding machine


8 for overmoulding in the beam

10
Public #_x000D_

10

11

12

13

N/A 7-Dec-12 First set-up made by K.Graafland


ENG. CHANGE
REVISION DATE DESCRIP
NUMBER
Public #_x000D_

Process Guidelines
ubes for plastic beams
Included in Process?
Comments (Supplier to complete
using drop list)

Raw material as mentioned on the released


No
Inalfa drawing

Check if the required certificates are available, link the


batch of material to a production order to secure the No
traceability

Parts to be checked according part drawing


No
(No damages, burrs, impressions, corrosion etc.)

Parts to be checked according part drawing


(No damages, burrs, impressions, corrosion etc.) and No
100% inspection on 3D shape (fixture)

Setting of the bending equipment should be


frozen/locked and adjustments only allowed after No
completed validation

Use of a "full form gage" is preferred No

This should be validated packaging to make sure that


the shape can not be deformed anymore in the No
packaging

No
Public #_x000D_

-up made by K.Graafland A.Mignoni


DESCRIPTION OF CHANGE APPROVED BY
Public #_x000D_

Key Process Guid


Plastic Frame

Step # Process

Procurement of raw material


1

2 Receiving inspection: raw material

3 Receiving inspection: Insert Bolt, Nut, Location Pin

4 Receiving inspection Steel insert braket

5 Drying the raw material

6 Verify humidity of granulate

7 Start up of injection molding process

8 Injection molding of the parts

Check the fit of insert parts in the injection molding


tool: parts to be put in the tool, open it again without
9 injection of plastic to check the parts on dents,
damages and missing.

Take out frame of the injection molding tool and


10 remove the injection sprue
(If applicable)
Public #_x000D_

Take out frame of the injection molding tool and


10 remove the injection sprue
(If applicable)

Input the part to cooling jig, and check the fit of part in
11 the cooling jig

12 Check the weight of the finished part

Inspect the parts for defects: part not completely filled,


13 deformed, burn marks, etc.

14 Check and marking insert parts missing in part

15 If deviations from the specification are detected, the


reaction plan should be put in place immediately

"First off release procedure" should be in place and


16 used to release the production batch

17 Place the frame in the packaging

18 Labels and other necessary documentation to be


added to the packaging.

20 Ship the filled packaging to the ware house


(Shipment department)

N/A 7-Dec-12 Update carried out by K.Graafland


ENG. CHANGE
REVISION DATE DESCRIP
NUMBER
Public #_x000D_

Process Guidelines
Plastic Frame
Included in Process?
Comments (Supplier to complete
using drop list)

Raw material as mentioned on the released


No
Inalfa drawing

Check if the required certificates are available, link the


batch of material to a production order to secure the No
traceability

Parts to be checked according part drawing


No
(No damages, burrs, impressions, corrosion etc.)

Parts to be checked according part drawing


(No damages, burrs, impressions, corrosion etc.) and No
100% inspection on 3D shape (fixture)

Time and temperature according supplier specification No

No

Check if the applicable documentation is available on


the work station like work instructions, control plan, No
process flow and order details

Check if the applicable documentation is available on


the work station like work instructions, control plan, No
process flow, valve sequenceand order details

By checking insert parts in the injection molding tool,


before and after the molding of the production batch, No
the risk of damaged insert parts is smaller.

If flashes occur on locations where it is not allowed,


No
they should be removed and tool submitted for repair
Public #_x000D_

If flashes occur on locations where it is not allowed,


No
they should be removed and tool submitted for repair

It must to be inserted in cooling jig within 30 sec after


No
injection for cooling effect

No

According agreed master samples/Drawing


No
specifications

According agreed master samples No

Corrective actions to be introduced. All parts in the


production line, ware house and shipment area should
be blocked until all corrective actions have been No
carried out and parts have been sorted on the found
deviation.

Quality department should make sure that release


procedure has been followed and the production batch No
can be released

No

No

No

carried out by K.Graafland A.Mignoni


DESCRIPTION OF CHANGE APPROVED BY
Public #_x000D_

Check Fixture Design Checklist

Supplier Status
Item Requirement-SEE IRS GSQAP-004-below are highlights only (Supplier to complete
using drop list)

The gage must be dimensionally stable and capable of maintaining stability without the use of unattached elements (such
asbrackets, cross bars, braces) throughout the life of the gage.
1 * Checking fixture base plate should be robust and stable, thickness prefreably >10 mm Not Agreed
* Material: Steel or Aluminium

All details must function freely without the use of excessive force and no allowable play.
2 Not Agreed
* Also keep in mind that the checking fixture is necessary (and should stay stable) during the complete product life time

3 Attaching features must function without binding or kinking and must be attached securely Not Agreed
(90 Newton minimum pull-off requirement, i.e normal operation should not cause details to separate from gage)

All elements locating and checking features must be clearly identified by Inalfa naming convention per Inalfa drawing.
4 * Identification lables should be attached in the right way, so that there is no risk that they will come loose during the life ime of Not Agreed
the checking fixture!

5 All non-gauging surfaces that may be subject to oxidation are to be coated to prevent deterioration through the life of the gage. Not Agreed

6 All sharp corners are to be broken 0.5mm or what is safely practical. Not Agreed

Tooling ball coordinate system required on all gages (x, y, z axis - in body position as required).
7 Not Agreed
* Preferable with tool ball values stamped on tags on non critical surfaces

CHECK FIXTURE DESIGN (SQD) Page 63 of 70 Printed: 09/13/2023


Public #_x000D_

Required inspection points (variable and attribute) are called out on Inalfa drawing

8 Not Agreed

Not Agreed

Not Agreed

CHECK FIXTURE DESIGN (SQD) Page 64 of 70 Printed: 09/13/2023


Public #_x000D_

Not Agreed

It is preferred that gage must be capable of being used as a CMM holding fixture
* Checking fixture can be used for checking during production with “Go-nogo features” (Attribute) and measuring clocks
9 Not Agreed
(variables)
* Part can be clamped on the datum points on this fixtures and used for CMM measurements

10 CMM access to underside of item required (minimum of 200mm of clearance to base plate) if doubling as a holding fixture. Not Agreed

11 Gage base plate must be flat within 0.08mm - 0,12 mm Not Agreed

Hardened steel bushings required for all check surfaces (unless otherwise specified by Inalfa).
* On feature 1, a flange can measured with a digital indicator in Z-direction. (“Variable” for checking during production)
12 * On feature 2, a flange can measured with a digital indicator in X-direction. (“Variable” for checking during production) Not Agreed
* With the CMM, the flange can be measured in both Z- and X -direction

13 Gage design must follow functional GD&T from drawings to locate items. Not Agreed

14 Net gauging surfaces and or datums shall be within 0.08 mm of math data Not Agreed

CHECK FIXTURE DESIGN (SQD) Page 65 of 70 Printed: 09/13/2023


Public #_x000D_

All clamping and swing templates (in open position) shall remain within the confines of the base or have appropriate guarding for
15 Not Agreed
protection of detail.

16 Variable data collection systems must have the ability for real time data review. Not Agreed

17 Gage build will not proceed without written authorization by Inalfa. Not Agreed

18 All gage concept/design drawings and math data must include the component in the section view for full understanding Not Agreed

19 Gage must be designed to function properly for the life of the component program (including service requirements). Not Agreed

Supplier compliance to approved designs, concepts, drawings, GR&R, and uniform gauging specifications are mandatory.
20 Not Agreed
Failure to comply could result in rejection of the gage.
Acceptable gage R&R will be less than 10%. Gage R&R values greater than 10% must be reviewed and signed off by Inalfa
21 (reference AIAG MSA manual for additional information / ANNOVA method is required for all Ford work and may be required by Not Agreed
other customers).
22 Gage certifications must be completed by a accredited metrology laboratory. Not Agreed

23 All gages must be dimensionally certified on a annual basis. Not Agreed

24 Detailed gage instructions with visual aids defining use of gage must be permanently attached to check fixture. Not Agreed

25 Gage must have Inalfa identification property tag (see Inalfa purchasing for tags and requirements). Not Agreed

26 See IRS GSQAP-004 gage specification for FULL detail (document available on Inalfa supplier portal). Not Agreed

CHECK FIXTURE DESIGN (SQD) Page 66 of 70 Printed: 09/13/2023


KEY CHARACTERISTICS MATRIX
Public
#_ x0 00 D_

"Special" Characteristics: Criteria requiring extra care (monitoring) to assure conformance.

1) Customer "Key (Special) Characteristic" Symbol: C

2) Inalfa "Key (Special) Functional Characteristic" Symbol: F

"Standard" Characteristics: Criteria requiring normal care (monitoring) to assure conformance.


Inalfa "Standard Characteristic" Symbol: NONE. All characteristics are considered "Standard", unless otherwise designated.

"Special" Characteristics Definition


(Customer) Key Characteristics are typically the key requirements that affect vehicle occupant safety and compliance with legislative (government) regulation. (FMVSS, E
C CNCA, etc.)

The number of assigned "C" characteristics, per commodity, shall be determined by Customer Specification, with no limit to quantity (typically, less than 5).

F (Inalfa) Key Functional Characteristics are the key dimensions and tests that determine, with > 90% certainty, if the item/assembly will meet all of it's "fit and function"
requirements. Includes Customer Characteristics (but not identified as Critical Characteristics).

The number of assigned "F" characteristics, per commodity, to be minimal (typically, less than 8).
Ppk / Cpk calculated in accordance with AIAG Statistical Process Control Manual (latest issue).

(Typical) Product Validation Requirements


Program Phase
Prototype Pre-Launch (FOT) Items Delivery of parts to IRS after PPAP Volume Production
(small sample runs) (PL1) tuning loop (PL2) (300pc run) (Ongoing or Annual)
Product Validation
Characteristic Category Requirement Requirement Requirement Requirement Requirem
Sample (Results Sample (Results Sample (Results Sample (Results (Results Rec
Sample Quantity
Quantity Reported to Quantity Reported to Quantity Reported to Quantity Reported to Retained by S
IRS) IRS) IRS) IRS) available by

Within
Within Statistical Specification Per Supplier
C Dimension All ≥30 All ≥30 Ppk ≥1.67 Cpk ≥1
Specification Analysis Control Plan
Pp>2

Per "Test Per "Test Per "Test


Within Within Within Per "Test
Test Requirements" 0 N/A Requirements" Requirements" Within Spec
Specification Specification Specification Requirements" Tab
Tab Tab Tab

Within
Within Statistical Specification Per Supplier
F Dimension All ≥30 All ≥30 Ppk ≥1.67 Cpk ≥1
Specification Analysis Control Plan
Pp>2

Per "Test Per "Test Per "Test


Within Within Within Per "Test
Test Requirements" 0 N/A Requirements" Requirements" Within Spec
Specification Specification Specification Requirements" Tab
Tab Tab Tab
Within Within
Dimension 6 6 Measurement 6 Measurement 6 6 Within Spec
Specification Specification
Standard Per "Test Per "Test Per "Test
Within Within Per "Test
Test Requirements" N/A 0 N/A Requirements" Requirements" Within Spec
Specification Specification Requirements" Tab
Tab Tab Tab

The supplier shall perform 100% inspection until Capability (Variable, Attribute, and Appearance) is proven with zero defects. Once the supplie
proven capability (long and short term), the Step Down Plan may go into effect with the approval of SQE. If in the event a defective part reaches
during the Safe Launch period, the Safe Launch Plan will re-start at 100% inspection until the Capability with zero defects criteria is proven and t
Step Down plan can be re-started at the beginning.

All "F" characteristics require proof of initial capability to 1.67 for Ppk
All "F" characteristics require long term capability to 1.33 for Cpk
All "F" characteristics require conformance to the typical stepdown chart for verification shown below.

Stepdown Timing Number of F's / Parts Checked

Stage To Be Determined
Initial Delivery 0-100 100% F's All Parts
100-600* 100% F's, 50% of the Parts
600-3000** 2 X's Normal Control Plan
Beyond 1st 3000 pc production Per Normal Control Plan

* If nonconformance is found, perform 100% inspection until capable


** If nonconformance is found, perform 100% inspection of lot and resume 100-600 frequency for next three (3) lots

13-Oct-14 Key Characteristics Flowchart revised to show all applicable FMVSS requirements plus ECE, CNCA, etc. J. Ros

KEY CHARACTERISTICS MATRIX(ENG) Page 67 of 70 Printed: 09/13/2023


10-Jul-13 Added PL1 and PL2 to headings per Toolbox Suggestion #147 J. Ros
10-Dec-12 Revised matrix to latest requirements Public #_ x0 00 D_
J. Ros
18-Sep-12 Removed Ppk from volume production column, added graphs for clarification J. Ros

23-Aug-11 Added capability and stepdown requirements (lines 34 - 46) J. Ros


19-Apr-11 Correct location of C and F symbols J. Ros

KEY CHARACTERISTICS MATRIX(ENG) Page 68 of 70 Printed: 09/13/2023


CHARACTERISTICS MATRIX Public #_ x0 00 D_

requiring normal care (monitoring) to assure conformance.


All characteristics are considered "Standard", unless otherwise designated.

ecial" Characteristics Definition


hat affect vehicle occupant safety and compliance with legislative (government) regulation. (FMVSS, ECE,

termined by Customer Specification, with no limit to quantity (typically, less than 5).

tests that determine, with > 90% certainty, if the item/assembly will meet all of it's "fit and function"
d as Critical Characteristics).

al (typically, less than 8).


ce with AIAG Statistical Process Control Manual (latest issue).

l) Product Validation Requirements


Program Phase
Volume Production
(Ongoing or Annual)

Requirement
(Results Recorded &
Retained by Supplier;
available by request)

Cpk ≥1.33

Within Specification

Cpk ≥1.33

Within Specification

Within Specification

Within Specification

riable, Attribute, and Appearance) is proven with zero defects. Once the supplier has
y go into effect with the approval of SQE. If in the event a defective part reaches Inalfa
at 100% inspection until the Capability with zero defects criteria is proven and then the
n can be re-started at the beginning.

7 for Ppk
r Cpk
pdown chart for verification shown below.

J. Rose

KEY CHARACTERISTICS MATRIX(ENG) Page 69 of 70 Printed: 09/13/2023


J. Rose
J. Rose Public
#_ x0 00 D_

J. Rose

J. Rose
J. Rose

KEY CHARACTERISTICS MATRIX(ENG) Page 70 of 70 Printed: 09/13/2023

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