Professional Documents
Culture Documents
Module: Body
Responsible:
Status:
Released
Version:
February 2015
Date:
01/02/2015
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.
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
4.
4.1
5.
5.1
5.2
5.3
5.4
5.5
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:
-
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.
Fig. 1
Multiple evaluation example (5 off)
Fig. 2
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:
-
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.
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,
The English translation is believed to be accurate.
In case of discrepancies, the German version is alone authoritative and controlling.
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
The English translation is believed to be accurate.
In case of discrepancies, the German version is alone authoritative and controlling.
2.5
E-ZP5A acceptances
For so-called special vehicles with special demands on appearance and impression such as
-
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:
Green range
Yellow range
Red range
<256
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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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%
03.11.2009
T oleranzausnutzung
<= 75%
> 100%
QS-Erprobungstrgerbau
und Vorserienprozess
GQB-5
11.12.2009
H. Mustermann / Firma
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3. Inspection reports
3.1
Firmenlogo
Firmenname
EA-Nummer
PRFBERICHT
Teilebenennung
Blatt
Projekt
Teilenummer
Prfberichtsnummer
Zeichnungsnummer
Datenstand
Zeichnungsstand
Geometriestand
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:
3.2
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3.3
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17
18
19
20
21
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4. Assembly (ZSB)
4.1
Inspection of joints
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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
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.
24
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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