q-release masterplan injection moulded cards v2.0 26may

Quality Masterplan - Basic tests for injection-moulded cards (Q-Release)V 2.0 26.05.2011

Test Method Standard

Customer requirement

Toshiba list incl. RoHS conformity 0-CS-Q0740VA04 Annex 2

Visual inspection Order specification

Customer specific requirements (incl. environment related substances)

Constancy of formulation (FTIR) Reference sample according order specification

Card dimension ID-1 heightCard dimension ID-1 width

Drawing / Order specification(according ISO/IEC 7810)

Card thickness ID-1

Card corner radius ID-1

Card edge

Dimensions and locations of the cavity Drawing / Order specification

Drawing / Order specification(analog ISO/IEC 7810 with restriction for injection moulded cards)

Drawing / Order specification(according ISO/IEC 7810)

Drawing / Order specification(according ISO/IEC 7810)

Depth of adherend Drawing / Order specification

Depth of blind hole Drawing / Order specification

Surface roughness Rz adherend Drawing / Order specification

Surface roughness Rz card surface Drawing / Order specification

Drawing / Order specification

Card warpage Drawing / Order specification

Colour

Surface profilereverse side module area

Reference sample according order specification

Light fastness

Bending stiffness

Order specification(analog DIN EN ISO 105-B02,exposure method 2)

Card dimensional stability and warpage with temperature and humidity

Order specification(according ISO/IEC 7810)

Order specification(according ISO/IEC 7810)

Resistance to chemicalsof cardbody

Order specification(according ISO/IEC 7810)

Resistance to heat (Cantilever method) Order specification

Bending strength-DIN G&D internal

ISO/IEC 7810

ISO/IEC 7810

Bending strength-ISOwith chip module(for new card materials part ofQ-qualification)

Torsion strength-ISOwith chip module(for new card materials part ofQ-qualification)

G&D internal

G&D internal

Abrasion resistance of surface printing G&D internal

Adhesive strength of surface printing G&D internal

Bending stressin axxis A/B(for new card materials part ofQ-qualification)

Bending stressat low temperature (-7°C)(for new card materials part ofQ-qualification)

ISO/IEC 7810

G&D internal

ISO/IEC 7810

G&D internal

Resistance to chemicalsof surface printing

Wipe resistance to alcoholof surface printing

Adhesion or blockingof surface printing

Resistance to plasticizerof surface printing (7 days / +50°C)

Light fastnesssurface printing

ISO/IEC 7810(analog DIN EN ISO 105-B02,exposure method 2)

Location of the ID-000 size cardin the ID-1 size cardbody

Drawing / Order specification(according ISO/IEC 7810)

Card thickness ID-000

Corner radius ID-000

Card dimension ID-000 heightCard dimension ID-000 width

Drawing / Order specification(according ISO/IEC 7810)

Drawing / Order specification(analog ISO/IEC 7810 with restriction for injection moulded cards)

Drawing / Order specification(according ISO/IEC 7810)

Bevel of ID-000

Order specification

Handling in terms of Plug-In break out G&D internal

G&D internal

Mailing simulation G&D internal

Drawing / Order specification(according ISO/IEC 7810)

Break out force ID-000(only the short ties)

Machine runabilityPrintabilityModule implantationPersonalisation

Quality Masterplan - Basic tests for injection-moulded cards (Q-Release)

Target Type/Number of samples

Test Procedure Value / Criteria sample size

Customer requirement see. spec. see spec. X

N/A N/A ./. X

0-CS-Q1574.4PA48 Order specification 0/120 X

pass/failcriteria

f/n

ID1 without

cavity and plug in

Customer requirement

120(30/cavity)

0-CS-Q1574.4PA06 0/1 1 X

ISO/IEC 10373-1 0/12 X

Correlation according order specification

height: 53,92 - 54,03 mmwidth: 85,47 - 85,72 mm

12(3/cavity)

ISO/IEC 10373-1 0,78 - 0,82 mm 0/12 X

ISO/IEC 10373-1 Drawing / Order specification 0/4 X

ISO/IEC 10373-1 ≤0,08 mm 0/4 X

0-CS-Q1574.4PA29 Drawing / Order specification 0/4 --

12(3/cavity)

4(1/cavity)

4(1/cavity)

4(1/cavity)

0-CS-Q1574.4PA30 Drawing / Order specification 0/4 --

0-CS-Q1574.4PA30 Drawing / Order specification 0/4 --

0-CS-Q1574.4PA51 Drawing / Order specification 0/4 --

4(1/cavity)

4(1/cavity)

4(1/cavity)

0-CS-Q1574.4PA51 Drawing / Order specification 0/4 --

0-CS-Q1574.4PA38 Drawing / Order specification 0/4 --

ISO/IEC 10373-1 Drawing / Order specification 0/4 X

0-CS-Q1574.4PA02 0/4 X

4(1/cavity)

4(1/cavity)

4(1/cavity)

DY = ±2,0Dx = ±0,002Dy = ±0,002

4(1/cavity)

0-CS-Q1574.4PA32 0/4 X

ISO/IEC 10373-1 ISO/IEC 7810 0/4 X

ISO/IEC 10373-1 0/4 X

ISO/IEC 10373-1 ISO/IEC 7810 0/12 12 X

≥4/3(woolscale/greyscale)

4(1/cavity)

4(1/cavity)

13 - 35mm (subjected to load)≤1,5mm (load removed)

4(1/cavity)

ISO/IEC 10373-1 Order specification 0/4 X

DIN 32753-1 ≥3000 cycles 0/8 X

ISO/IEC 10373-1 0/16 16 X

ISO/IEC 10373-1 0/5 5 X

4(1/cavity)

8(2/cavity)

≥1000 cycles(end of the test:max. 8000 cycles)

≥1000(end of the test:max.10000 cycles)

0-CS-Q1574.4PA23 0/20 20 X

0-CS-Q1574.4PA22 0/10 10 X

0-CS-Q1574.4PA16 ≥200 cycles 0/5 5 X

0-CS-Q1574.4PA35 0/5 5 X

Adhesion of module to cardat 3,0mm

electrical function, adhesion of module etc.

Only a few, small detachments are allowed

ISO/IEC 10373-1 ISO/IEC 7810 0/12 12 X

0-CS-Q1574.4PA45 No delamination 0/3 3 X

ISO/IEC 10373-1 ISO/IEC 7810 0/5 5 X

0-CS-Q1574.4PA44 No delamination 0/8 8 X

0-CS-Q1574.4PA32 0/4 4 X

ISO/IEC 10373-1 0/4 --

≥4/3(woolscale/greyscale)

top edge ID-1/ID-000:16,38 - 16,58 mmleft edge ID-1/ID-000:6,15 - 6,35 mm

4(1/cavity)

ISO/IEC 10373-1 0/12 --

ISO/IEC 10373-1 0,78 - 0,82 mm 0/12 X

ISO/IEC 10373-1 0,9 - 1,1 mm 0/4 --

height: 14.90 - 15,10 mmwidth: 24,90 - 25,10 mm

12(3/cavity)

12(3/cavity)

4(1/cavity)

ISO/IEC 10373-1 0/4 --

0-CS-Q1574.4PA85 11 - 30 N 0/16 --

0-CS-Q1574.4PA85 Order specification 0/12 --

0/2000 --

0-CS-Q1574.4PA79 0/320 --

angle: 45° ± 2°length: 2,9 - 3,1 mm

4(1/cavity)

16(4/cavity)

12(3/cavity)

Evaluation according production standards

Processability must be guaranteed

2000(500/cavity)

No complete separation of Plug-In from the ID-1 cardbody

320(80/cavity)

Type/Number of samples Equipment Information

Type of equipment needed internally

X X ./.

X X Verification of supplier certificate ./.

X X X ./. 1.0

ID1 withinjection moulded

cavity

ID1 withinjection moulded

cavity andinjection moulded plug in

Test in

central

testlab

Estimated effort

for the

discrete test [hour

s]

Customer requirements that exceed the requirements of this Masterplan

X X X 2.0

X X X 1.0

Device for the FT-IR analysis(e.g. Perkin Elmer FT-IR Spectrometer),Laminating-press and -plates

Digital dial indicator (accuracy 0,003 mm / supplier e.g. Mitutoyo),Ceramic-gauge blocks (grade 0 / supplier e.g. Mitutoyo),Measuring plate,Profilprojector

X X X 0.5

X X X Coordinate reading microscope 1.0

X X X 1.0

X X X Coordinate reading microscope 2.0

Digital micrometer (operating rangemin. 0-5mm/supplier e.g. Mitutoyo)

Surface profile measuring device(e.g. Hommel)

X X X 0.5

X X X 0.5

X X X 2.0

Digital dial indicator (accuracy 0,003 mm / supplier e.g. Mitutoyo),Measure head with a diameter of 1,5 mm

Digital dial indicator (accuracy 0,003 mm / supplier e.g. Mitutoyo),Measure head with a diameter of 1,5 mm

Surface rouhgness measuring device (supplier e.g. Mitutoyo or Hommel)

X X X 1.0

X X X 1.5

X X X Test stand "card warpage" 0.5

X X X 1.5

Surface rouhgness measuring device (supplier e.g. Mitutoyo or Hommel)

Surface profile measuring device(e.g. Hommel)

Colour-measuring instrument(e.g. Minolta Chroma-Meter II Reflectance or Gretag SpectroEye),Specified base for colour measuring

X X X 1.0

X X X 2.0

X X X Test stand "bending stiffness" 1.0

X X X 4.0

UV-exposure unit (e.g. Suntest CPS),Woolscale stripes,Grey scale (supplier eg. Beuth verlag)

Climatic chamber (-35°C and +50°C/95%r.H.),Test stand "card warpage" and "card dimension"

Solutions according ISO/IEC 10373-1Exhaust hood

X X X 2.0

X -- X Bend tester DIN 2.0

X -- X Bend tester ISO 6.0

X -- X Torsion tester ISO 2.0

Thermal chamber with operating range0-200°C (supplier e.g. Vötsch),Card holder according ISO/IEC 10373-1,Height gauge

X -- X 1.0

X -- X 1.0

X X X 1.0

X X X Adhesive tape Tesa 4101PV2 + Cutter 1.0

Manual bending equipment"Bending stress A/B" for 1,5 and 3mm

manual bending equipment"Bending stress -7°C"

Abrasion resistance tester with sandpaper according german health card specification

X X X 4.0

X X X 0.5

X X X 1.0

X X X 1.0

Solutions according ISO/IEC 10373-1Exhaust hood

Climate chamber with operating range5-98 % rel. Humidity and -40 to 100°C (supplier e.g. Vötsch),Weight acc. to ISO/IEC 10373-1

Thermal chamber (+50°C),plasticizer films,weight: 1,25 kg

X X X 1.0

-- X X Coordinate reading microscope 1.0

UV-exposure unit (e.g. Suntest CPS),Woolscale stripes,Grey scale (supplier eg. Beuth verlag)

-- X X 1.0

X X X 0.5

-- X X Coordinate reading microscope 1.0

Digital dial indicator (accuracy 0,003 mm / supplier e.g. Mitutoyo),Ceramic-gauge blocks (grade 0 / supplier e.g. Mitutoyo),Measuring plate,Profilprojector

Digital micrometer (operating rangemin. 0-5 mm / supplier e.g. Mitutoyo)

-- X X Coordinate reading microscope 1.0

-- X X Coordinate reading microscope 1.0

-- X X ./. ./.

-- X X ./.

-- X X Test equipment for mailing simulation 4.0

Production equipment for printing, module implantion and personalisation

Equipment Information

Name of external testlab (functional test always performed at central test lab)

Salt mist storage:IABG Ottobrunn (800 Euro)

Salt mist storage:IABG Ottobrunn (800 Euro)