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Supplier Handbook for prototypes

Module: Body

Responsible:

Marco Bhrig, GQE-V/P

Status:

Released

Version:

February 2015

Date:

01/02/2015

Supplier Handbook for prototypes


Module: Body

Table of contents
1.

Requirements............................................................................... 3

1.1
1.2
1.3
1.4

Documentation .............................................................................................. 3
Inspection equipment suitability ..................................................................... 5
Quality requirements for drawn and body components ................................. 5
Assessment of producibility (deep-drawing simulation) ................................. 6

2.

Inspection and evaluation ............................................................ 6

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.
3.1
3.2
3.3

Requirements for individual parts .................................................................. 6


Requirements for assemblies ........................................................................ 6
Measurement programs ................................................................................ 7
E-ZP5 acceptances ....................................................................................... 8
E-ZP5A acceptances ..................................................................................... 9
Measurement fixtures .................................................................................... 9
Material thinning .......................................................................................... 10
Dimensional accuracy index (MI) ................................................................ 11
MI evaluation for target tracking and target parameters for assemblies ...... 13
Inspection reports ........................................................................................ 14
Inspection report cover sheet ...................................................................... 14
Graphical depiction of the orientation in accordance with RPS ................... 15
Graphical depiction of the target data and deviations .................................. 16

4.

Assembly (ZSB) ......................................................................... 23

4.1

Inspection of joints ....................................................................................... 23

5.

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

5.1
5.2
5.3
5.4
5.5

Inspection of hot-formed parts ..................................................................... 24


Material specimens...................................................................................... 25
Parts marking .............................................................................................. 25
Processes and materials ............................................................................. 26
Production ................................................................................................... 26

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Supplier Handbook for prototypes


Module: Body

1. Requirements
The contractor shall designate a Q contact partner for the quality assurance department (Q)
of the contractee. This Q contact partner shall establish contact with the quality assurance
department of the contractee in order to agree the Q requirements.
1.1
Documentation
The basic responsibility for documentation lies with the party that creates an individual part or
constructs an assembly or makes changes thereto (contractor). Documentation and
inspection requirements will be agreed between the contractee and contractor.
Evaluations for the assembly main groups: It is fundamentally necessary to produce
individual evaluations (measurement result for one unit) and collective evaluations
(measurement results for 5 units or more).
Individual evaluations comprise the following:
-

target value, actual value, tolerance, deviation

Collective evaluations comprise the following:


-

target value, deviations (5 units or more)

Furthermore, red range evaluations (see figure 3) shall be performed, followed up, and made
available in updated form to the contractee at defined time intervals (for example weekly),
over the entire period.
Red range lists comprise the following:
-

All measurement points of one assembly, and the deviations thereof, shall be
presented in accordance with the construction sequence.
To visualize the dimensional accuracy, the deviations of the inspected features
shall be provided with a coloured background (green/yellow/red). Regarding
gradation, see dimensional accuracy index.

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Supplier Handbook for prototypes


Module: Body

Individual evaluation example

Fig. 1
Multiple evaluation example (5 off)

Fig. 2

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Supplier Handbook for prototypes


Module: Body

Red range list example

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

1.2
Inspection equipment suitability
The following limit values must be adhered to:
for single-stand measurement installations: MPEE = 30 m + L/40 m 100 m, and
for double-stand measurement installations MPEED = 40 m + L/40 m 120 m
The supplier bears responsibility for documenting these processes.
1.3
Quality requirements for drawn and body components
For drawn and body components, the following requirements, among others, must be
complied with:
-

test parts conforming to drawings


absence of cracks
no inadmissible welds
no bulging at spot and connection surfaces no drawing and crimping folds
no material displacement and overlap
no inadmissible material weakening at the radii or transitions
no inadmissible material reduction

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Module: Body

no inadmissible heat treatment


delivery in a corrosion-free state
deburred
With regard to subsequent painting, the component surface shall have no visible
and perceptible (tangible) flaws
For crash-relevant components (which will be designated in the contract by the
responsible contact partner [see general part, section 1.5]), material tests shall be
carried out. A target/actual comparison shall be established, with a statement
regarding compliance with requirements.

1.4
Assessment of producibility (deep-drawing simulation)
Further to the specifications in the Supplier Handbook for prototype parts (General part), this
part goes into greater detail as regards how the assessment of producibility should be
performed for particular metal panel parts. Here, the most definitive method is the deepdrawing simulation. The deep-drawing simulation shall be performed for certain parts (which
will be designated in the contract by the responsible contact partner [see general part,
section 1.5]) in accordance with VW standard 01170: 2007-02, and results which infer
restricted producibility or non-producibility shall be made available, at no cost, to the quality
assurance department of the respective prototyping/pre-series centre. The same applies to
parts which are not included in the list but which likewise exhibit only limited producibility or
non-producibility. Limited producibility or non-producibility is to be understood as: crack
formation, fold formation and/or bulge formation within the part based on the simulation.

2. Inspection and evaluation


2.1
Requirements for individual parts
Unless agreed otherwise with the respective quality assurance department of the
prototyping/pre-series centre, the supplier is solely responsible for defining the features
inspected and the inspection scope in accordance with the manufacturing method in order to
ensure their supply quality. The measurements, inspections and qualitative evaluations of
prototype parts shall fundamentally be performed in accordance with the drawing
documentation approved by the responsible contact partner (see general part, section 1.5)
and/or in accordance with the applicable data set. The components to be measured and the
inspection intensity will be designated by the above-mentioned contact partner, and shall be
documented by way of inspection reports.
2.2
Requirements for assemblies
For statements regarding manufacturing quality and testability, measurements must be
performed for an assembly; it is the sole responsibility of the contractor to perform said
measurements. In the event of significant deviation outside tolerances, suitable reworking
measures shall be implemented in agreement with the contractee.

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Supplier Handbook for prototypes


Module: Body

The measurement requirements and the tolerances shall be agreed with the contractee. If
appropriate, inspection requirements applicable in the case of assembly main groups, such
as for example inspection feature plan (PMP) and functional dimension catalogue (FMK),
which are then provided by the contractee, shall be taken into consideration. The initial
measurement must fundamentally be completed and documented before any reworking. In
the event of any reworking, a further measurement (final measurement) shall be performed.
In the case of assembly subgroups (which do not have a PMP from the contractee), the
contractor bears sole responsibility for defining the inspected features (see B - General Q
part, section 3.3). The contractee reserves the right, if necessary, to agree with the
contractor which features shall be subjected to inspection and measurement. The contractor
bears sole responsibility for the measurements, any measurement programs, documentation
and any manufacturing-monitoring activities.
Repeatability of the measurements must be ensured in all situations. The measurement
report must document the release status of the assembly.
Inspection intensity for assembly main groups
The inspection intensity for the assembly main groups can be found in the brand-specific parts!
Inspection intensity for assembly subgroups
From a price aspect, it is basically the case that one measurement report per subassembly is
expedient. The contractee will define the final inspection intensity.
It is basically the case that, if multiple measurements are necessary per subgroup in order to
achieve the quality aims, the costs of additionally required measurements shall be borne by
the contractor. The contractee shall bear the costs for only one measurement. Basically, the
first assembly shall be documented by way of one measurement report. To achieve process
reliability at an early stage, measurements shall be performed with increased regularity in the
initial construction phase. The assemblies to be measured will be defined by way of the
vehicle list/construction sequence.
A reduction in inspection intensity may be implemented only after prior agreement with the
contractee.
2.3
Measurement programs
For the assembly main groups of box-type bodyshell, UB2 (platform), attachment parts
(doors, lids, flaps), interior and exterior side parts, inspection requirements (PMP and FMK)
are provided by the contractee. In accordance with these inspection requirements, the
contractor shall provide CNC measurement programs (in DMIS format), taking into
consideration the measurement point names, the measurement principles (VW standard
101 15) and the RPS orientations (VW standard 010 55), at the latest three days before initial
measurement.
Upon the initial measurement, the measurement programme will be run-in (debugging, fault
elimination). The measurement programme will be accepted by the contractee after
discussion of the measurement report produced and plausibility checking. The contractor
shall notify the contractee of the appointment for the first measurement, for joint acceptance,
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Supplier Handbook for prototypes


Module: Body

at least one week in advance, and shall finally communicate the appointment (including
details of the time) at the latest 2 days in advance. Measurement results must be exportable
in a format agreed with the contractee (for example DMIS format DMO).
Compatibility of the measurement programs between contractor and contractee must be
agreed in advance. The measurement programs and evaluation requirements (see
documentation) will be transferred to the contractee at no cost if required.
2.4
E-ZP5 acceptances
For E-ZP5 (body before painting), for the prototypes and possibly other test vehicles (for
example development vehicles, concept vehicles, substructure...), acceptance shall be carried
out by the responsible quality control department of the contractor (with for example E-ZP5
checklist, signature card, weight card, E-ZP5 acceptance report). The required acceptance
appointment shall be notified to the contractee and test vehicle customer one week in advance,
and finally communicated (including details of the time) at the latest 2 days in advance.
This encompasses the visual and dimensional assessment of the joints (joint dimension and
flushness) and a dimensional inspection of the sealing and roof channel dimensions in
relation to the technical specifications. Furthermore, the weight measurement of the body
and of the body assemblies shall be agreed with the contractee, performed and documented
in the weight card.
Said documents are documented on a vehicle-specific basis by the quality assurance
department of the contractor for the Volkswagen brand in the EASy4Q system (electronic
vehicle identity card). In the event of deviations and objections arising from the inspection,
the contractor is responsible for bearing the costs of any reworking. Defects that arise or are
identified for the first time during the course of the vehicle acceptance run or during
subsequent use shall likewise be rectified at the cost of the contractor (if no subsequent
design changes have been made by the contractee).
Only for so-called special vehicles with special demands on appearance and impression
such as
- Overall release vehicles (GFF)
- Exhibition and press vehicles
- Board of Management vehicles
shall an E-ZP5 audit (bodyshell audit) be performed by a certified auditor (conforming to
Group standard) in agreement with the quality assurance department of the contractee.
For a qualitative assessment, in the case of special vehicles, the following installation parts,
for example, must be installed (if the deadline allows) for E-ZP5 acceptance:
-

Bumpers
KU assembly carrier
Fuel filler flap module
Headlights
Tail light cluster
Door seals
Lock parts for flaps and doors
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Supplier Handbook for prototypes


Module: Body

Panoramic sliding roof/panoramic tilting roof


Roof railing
Windows
Outer panels of the A/B/C pillars

2.5
E-ZP5A acceptances
For so-called special vehicles with special demands on appearance and impression such as
-

Overall release vehicles


Exhibition and press vehicles
Board of Management vehicles or special vehicles

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


(conforming to Group standard) in agreement with the quality assurance department of the
contractee.
For the first three bodies of a new construction stage/integration stage and for all special
vehicles, endurance running vehicles, acoustics vehicles and corrosion vehicles, a
corrosion/functional inspection, or an audit (acoustic bulkhead, fine and coarse seam sealing,
deadening mats, KTL coating etc.), will be performed by the quality control department of the
contractor (with E-ZP5A checklist). The summons to the inspections shall be issued at least
one week in advance. In the event of deviations and objections arising from the inspections
and audits, the contractor is responsible for bearing the costs of any reworking. Defects that
arise or are identified for the first time during the course of the vehicle acceptance run or
during subsequent use shall likewise be rectified at the cost of the contractor (if no
subsequent design changes have been made by the contractee).
2.6
Measurement fixtures
If measurement fixtures are requested by the contractor, these shall be labelled as property
of Volkswagen AG (labelling of special production equipment for prototypes in conformance
to VW 34022).
For the assembly subgroups/UB2/box-type bodyshell and attachment parts (doors, lids,
flaps, wings), it is fundamentally the responsibility of the contractor to provide measurement
fixtures, unless the contractee makes preferred series measurement fixtures available for the
construction period. The costs of the measurement fixtures must be listed separately in the
quotation. The required assembly subgroup measurement fixtures shall be agreed with the
contractee after commissioning.
In the case of the UB2 platform and box-type bodyshell measurements, fixture columns shall
be used which allow for the degrees of freedom of the RPS specifications.
To ensure a reproducible basis for these measurements, the Z vehicle coordinates must be
kept on the RPS surfaces by way of hook clamps.

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Supplier Handbook for prototypes


Module: Body

2.7
Material thinning
The admissible material thinning is dependent on the mechanical/technological
characteristics, for example expansion and forming limit, predefined by the material.
The limit values can be found in DIN EN 10143, DIN EN 10131, VW 01070 and VW 01170.
Material thickness inspection is included in the test report. The greatest reduction of material
thickness in % must be stated under point C on the cover sheet of the inspection report.
Those regions which are subjected to intense load in the drawing process will be inspected.

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2.8
Dimensional accuracy index (MI)
The dimensional accuracy index (MI) constitutes a summary of the measurement results.
These are graded into green, yellow and red ranges.

The result of the enumeration in the corresponding range shall be documented on the cover
sheet of the inspection reports as follows:
Example:

Explanation:

Dimensional accuracy index


93% / 7% / 0% / 135 MP

93% = Green range


7% = Yellow range
0% = Red range
135 MP = Number of measurement points

Green range

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

Yellow range

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

Red range

<256

outside the tolerance (reworking range).

The greatest deviations shall be stated on the inspection report cover sheet (under C),
stating the measurement point number and the measurement report page. The number of
measurement points that lie outside double the tolerance shall be stated.

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12

The gradation of the Green, Yellow, and Red ranges is dependent on the tolerance
utilization in %:

Sollwert

Toleranzverhltnis
Beispiel +1,0 / -1,0 mm Toleranz
0,25

symmetrisches Toleranzfeld

-1

0,25

0,25

asymmetrisches Toleranzfeld

-0,75

0,25

0,25

asymmetrisches Toleranzfeld

0-75%

+1

+1,25

0,25

75-100%

+2

>100%

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2.9
MI evaluation for target tracking and target parameters for assemblies
For the assemblies evaluated in accordance with PMP/FMK, the contractor will issue a
weekly MI evaluation, in accordance with construction sequence, for BM (report
measurements), FM (functional dimensions), and BM + FM total.
The target parameters shall be agreed with the contractee, or looked up in the brand-specific
part, for each construction stage.
The target parameter shall be depicted by means of a line as in the example.
Example (target parameter with 75%)

Mahaltigkeit Funktionsmae
VWxxx Kastenrohbau Abgabestand
08 M essungen

95 FM
100%
9

90%

12

11

10

14

12

15
7

18

80%

M ahaltigkeitsindex in %

7
13

9
13

10

70%
60%
50%
40%

77

82

83

80

85

82
75

75

72

30%
20%

M ittelwert

VW xxx

VW xxx

VW xxx

VW xxx

VW xxx

VW xxx

VW xxx

0%

VW xxx

10%

Z iel 75% grn + gelb

03.11.2009

T oleranzausnutzung

<= 75%

> 75% u. <=100%

> 100%

Zeitraum : Jun 2009 - Nov 2009

QS-Erprobungstrgerbau
und Vorserienprozess
GQB-5

11.12.2009

H. Mustermann / Firma

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3. Inspection reports
3.1

Inspection report cover sheet

Firmenlogo

Firmenname
EA-Nummer

PRFBERICHT
Teilebenennung

Blatt

Projekt

Teilenummer

techn. Ansprechpartner / Auftraggeber

Prfberichtsnummer

Zeichnungsnummer

Datenstand

Zeichnungsstand

Geometriestand

Stck geliefert / geprft

Werkstoff

Gewicht
verwendbar fr:

von Nr.
Auftrags-/
Bestellnummer

Lieferant (Lieferantennummer)

bis Nr.
Lieferschein/vom

Los-Nr.

Prfteil-Nr.

Generationsstand/Werkzeugtyp
Absprachestand vom:

abgestimmt mit:
Name:

Firma:

Abteilung:
A

Grund der

B Ausrichtung

Prfergebnis

Telefon:
D Bemerkung

Prfung

Qualittsstatus:

Prfer:

Verteiler:

Datum:
Unterschrift:
Telefon:
Mahaltigkeits-Index:

Stellungnahme
Auftraggeber

Geprft:
Datum:
Unterschrift:
Telefon:

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3.2

Graphical depiction of the orientation in accordance with RPS

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3.3

Graphical depiction of the target data and deviations

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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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Supplier Handbook for prototypes


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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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Supplier Handbook for prototypes


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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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Supplier Handbook for prototypes


Module: Body

The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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Supplier Handbook for prototypes


Module: Body

The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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Supplier Handbook for prototypes


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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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4. Assembly (ZSB)
4.1

Inspection of joints

Weld spot inspection:


Documentation of strength of spot-weld joints on assemblies shall be ensured, and confirmed
on the inspection report cover sheet under point "D", in accordance with standards VW
01105-1, VW 01105-2, VW 01105-4, PV 6702 and data sheet DVS 2916. Non-destructive
testing methods can be used but must be verified by destructive tests at regular intervals. A
visual inspection shall be performed for every component. To ensure process reliability, a
weld sample shall be produced, and subjected to destructive testing, for each metal panel
pairing. If required, these samples shall be made available to the respective brand of the
Volkswagen Group (Audi, SEAT, KODA, Volkswagen). The procedure for projection-weld
joints is similar to that for spot-weld joints (see standard PV 6727).
The first 3 units/assemblies of a new construction lot shall be inspected using ultrasound to
verify the welding process.
Crash bodies represent a special case. Every crash unit must be inspected using ultrasound.
Those weld spots of said units which are not OK must be documented by photograph,
specifying the weld spot names, and made available immediately to the contractee. Reworking
of said weld spots shall be performed only in agreement with the contractee. Further inspection
activities (for example hydropulse, endurance tests) shall be agreed with the contractee.
Inspection of laser-welded joints and laser-brazed joints:
Documentation of strength of laser-welded joints and laser-brazed connections on
assemblies shall be ensured, and confirmed on the inspection report cover sheet under point
"D", in accordance with standards VW 01141-1, VW 01143-1, PV 1602, PV 6709 and PV
6719. A visual inspection shall be performed for every component. To ensure process
reliability, a weld/braze sample shall be produced, and subjected to destructive testing, for
each welded/brazed connection.
If required, these samples shall be made available to the respective brand of the Volkswagen
Group (Audi, SEAT, KODA, Volkswagen). *
Inspection of studs and weld and rivet nuts:
Documentation of strength of the connections shall be ensured, and confirmed on the
inspection report cover sheet under point "D", in accordance with standards VW 01107, VW
01103, VW 60431, VW 60435 and VW 60564. A visual inspection shall be performed for
every component. To ensure process reliability, a sample shall be produced, and subjected
to destructive testing, for each connection.
If required, these samples shall be made available to the respective brand of the Volkswagen
Group (Audi, SEAT, KODA, Volkswagen). *
Inspection of connections produced by gas-shielded welding:
Documentation of strength of connections produced by gas-shielded welding on assemblies
shall be ensured, and confirmed on the inspection report cover sheet under point "D", in
accordance with standards VW 01106-1, VW 01106-2, VW 01106-3 and PV 6728. A visual
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inspection shall be performed for every component. To ensure process reliability, a weld
sample shall be produced, and subjected to destructive testing, for each weld joint.
If required, these samples shall be made available to the respective brand of the Volkswagen
Group (Audi, SEAT, KODA, Volkswagen). *
Inspection of adhesive connections:
Documentation of strength of adhesive connections on assemblies shall, in accordance with
standards PV 2043, PV 2047 and PV 2049, be ensured and confirmed on the inspection
report cover sheet under point "D".
A visual inspection shall be performed for every component. To ensure process reliability, a
sample shall be produced, and subjected to destructive testing, for each adhesive connection.
If required, these samples shall be made available to the respective brand of the Volkswagen
Group (Audi, SEAT, KODA, Volkswagen). *
* Assemblies for crash vehicles: for crash vehicles, connections that are not OK shall be
documented in detail with photographs, and the further procedure shall subsequently be
agreed with the contact partner (see general part, section 1.5).
The following inspection specifications shall be adhered to:
PV 6702 Spot-weld joints
DVS 2916 Inspection of spot-weld joints
PV 1602 Laser-beam and plasma brazing of body assemblies
PV 6719 3-panel welding (laser-beam weld joints)

5. Hot-formed parts
5.1

Inspection of hot-formed parts

Material thinning
The maximum permissible amount of partial material thinning is 20%, irrespective of
panel thickness.
Crash-relevant components may have a higher requirement than the 20% rule:
Guideline for thermoformed and hot-formed prototype parts and project-specific specifications.
It is the responsibility of the manufacturer to ensure that the material thinning is not exceeded.
Visual inspection
All deliveries of hot-formed parts must be visually inspected for flawless quality. The
inspection shall be performed at an ergonomically dimensioned and well-illuminated
inspection station. The quality requirements for deep-drawn and body parts stated in the
Supplier Handbook for prototype parts apply.

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Laboratory inspection report


See applicable documents to determine the areas from which samples must be taken from
the component for testing tensile strength, hardness and material thickness and creating
microsections.
Testing intensity shall be agreed with the responsible contact partner depending on
quantities and delivery batches (see General part, section 1.5). Additional tests which are
necessary to document stable manufacturing processes shall be performed on a cost-neutral
basis, and shall be incorporated into the process documentation by way of the form.
It must be possible to assign the tests to a delivery batch, and the tests must be identified in
the same way as parts. The results of the tensile test must be presented as a stress-overelongation diagram. Hardness tests will be documented by the laboratory in Vickers (HV)
(see +20).
5.2
Material specimens
Material specimens used to determine welding parameters shall be provided by the supplier
(e.g. resistance spot welding, projection welding, stud welding).
5.3
Parts marking
The marking of the components with batch/component number (1/19) must be such that the
durability and legibility is ensured over the service life of the parts (for example by stamping
or engraving). Subsequent work procedures must not affect the legibility of the marks. Every
component must be uniquely assigned to the Process documentation of hot-formed
components and to the test samples.
Labels must be attached to metal panel parts as follows:
-

by fabric tape
by stickers which can be removed without residue by a single pull-off action (not for
thermoformed parts)
by detachable cable ties

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

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5.4
Processes and materials
The supplier shall define parameters and regulation ranges relevant to the manufacturing
process and verify these by way of by capability documentation. Compliance with
parameters in prototype part production must be documented.
- Material (composition and measured thickness of blank)
- Blank tolerances (according to DIN EN 10131)
- Oven temperature*
- Period that blank remains in oven
- Blank temperature after positioning on the tool*
- Tool temperature at the time of the deformation process*
- Part temperature upon removal from the tool*
- As appropriate, size and location of provisions on tool to impede possible spring-back
* Automated temperature measurement and documentation shall be sought!
See annex: process documentation for hot-formed components
Compliance with the material data specified in the drawings must be verified (e.g. concerning
TL provisions or concerning banned heavy metals). Batch-related influences on product
quality, such as input materials and process-related influences, must be considered when
defining the scope of inspection.
5.5
Production
Hot-formed parts are produced by direct drawing (TL 4225).
Retroactive manual reworking of the component form (stretching or drawing-in of material,
processing by hammering etc.) is not admissible.
Approval must be obtained from the contractee in the event of deviations from the production
method. This approval must be renewed and documented in the process documentation
every time the data version (TM) is changed.

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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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The English translation is believed to be accurate.


In case of discrepancies, the German version is alone authoritative and controlling.

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In case of discrepancies, the German version is alone authoritative and controlling.

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