ppap sample documents
TRANSCRIPT
PRODUCTION PART APPROVAL PROCESS (PPAP)
SSuupppplliieerr NNaammee//LLooccaattiioonn//SSuupppplliieerr CCooddee::
Bourns Electronics Ireland
Mahon Industrial Estate
Blackrock
Cork
Ireland
SSuupppplliieerr PPaarrtt NNuummbbeerr::
PPaarrtt//FFaammiillyy DDeessccrriippttiioonn::
SSuubbmmiissssiioonn DDaattee::
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 1/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
CCOONNTTEENNTTSS
TTSS1166994499 CCEERRTTIIFFIICCAATTIIOONN
PPAARRTT SSUUBBMMIISSSSIIOONN WWAARRRRAANNTT
DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART
CCOONNTTRROOLL PPLLAANN // MMEEAASSUURREEMMEENNTT SSYYSSTTEEMM SSTTUUDDIIEESS
PPAARRTT DDRRAAWWIINNGG && DDIIMMEENNSSIIOONNAALL RREEPPOORRTT
RREESSIISSTTAANNCCEE MMEEAASSUURREEMMEENNTT RREEPPOORRTT
MMAATTEERRIIAALL CCEERRTTIIFFIICCAATTIIOONN && IIMMDDSS AAPPPPRROOVVAALL
AAPPPPEEAARRAANNCCEE RREEPPOORRTT
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 2/29
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 3/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
PART SUBMISSION WARRANT
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 4/29
Bourns Part Number Customer Part Number
Dated
Additional Engineering Changes Dated N/A
Shown on Drawing Number Purchase Order No.
SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION
Supplier Name
Customer Name/Division Street AddressBLACKROCK CORKCity State Zip
Note: Has this part been reported in IMDS (or equivalent)?
REASON FOR SUBMISSIONInitial submission Change to Optional Construction or MaterialEngineering Change's) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or additional Change in Part ProcessingCorrection of Discrepancy Parts produced at Additional LocationTooling Inactive > than 1 year Last PSW > 1 year old
Other - please specifyREQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.Level 2 - Warrant with product samples and limited supporting data submitted to customer.Level 3 - Warrant with product samples and complete supporting data submitted to customer.Level 4 - Warrant and complete supporting data submitted to customer.Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTSThe results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all drawing and specification requirements: (If "NO" - Explanation Required)
DECLARATIONI affirm that the samples represented by this warrant are representative of our parts, have been made to the applicableProduction Part Approval Process Manual 3rd Edition Requirements.
EXPLANATION/COMMENTS:
Print Name Title Fax No.
Supplier Authorized Signature Date
Supplier E-mail Address
FOR CUSTOMER USE ONLY (IF APPLICABLE)Part Warrant Disposition:
Customer Name Customer Signature Date
ua tities until functional approval or waiver is nom customer.
Part Submission Warrant
Sample co ordinator
BOURNS ELECTRONICS
MAHON INDUSTRIAL ESTATE
NONE
Phone No.
Safety and/or Government Regulation
Engineering Drawing Change Level
Dimensional Materials/Function Appearance
Yes No
NoYes
YES NO
Approved Rejected
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 5/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
DDEESSIIGGNN FFMMEEAA // PPRROOCCEESSSS FFMMEEAA // PPRROODDUUCCTTIIOONN PPRROOCCEESSSS FFLLOOWW CCHHAARRTT
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 6/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Bourns Electronics (Irl) FMEA Number : DFM-C0002
FMEA Revision : Rev G
Failure Mode & Effects Analysis ECO No.: 05-0046Item : Automotive Fuel Level Sensor Design FMEA Prepared By : S P O'SullivanModel :3710X-XXX, 3714X-XXX FMEA Date (Rev.) 21-Feb-05Core Team : JL, MO'B, SPOS, PB, EO'R FMEA Date (Orig.) 01-Aug-96
Design Functions & Requirements
Potential Failure Mode
Potential Effect(s) of
Failure
Sev
Class
Potential Cause(s) /
Mechanism(s) of Failure
Occur
Current Design Controls
Detect
RPN
Recommended Actions
Responsibility & Target
Completion Date
Actions Taken
Sev
Occ
Det
RPN
Resistor Too Low Gauge Inaccuracy 7 M Incorrect Design 4 PPAP sample
qualification 1 28
Too Low Gauge Inaccuracy 7 M Low ohms/square 4 PPAP sample
qualification 1 28
Too high Gauge Inaccuracy 7 M Incorrect Design 4 PPAP sample
qualification 1 28
Too high Gauge Inaccuracy 7 M Low ohms/square 4 PPAP sample
qualification 1 28
Resistor value Drift Gauge Inaccuracy 6 M Material unsuitable
for environment 5PPAP sample
qualification, customertests
2 60
Termination Open circuit No gauge reading 8 C Incorrect Design 5
Design Rules, PPAP, Gerber View, Artwork
Inspection1 40
Open circuit No gauge reading 8 C
Incorrect material selection, Premature
element wear2 PPAP sample
qualification 2 32
Probe mark on resistorcard.
Eratic opencircuit 8 C
Positioning of probe points on wiper travel
area.4 Not listed. 5 160
Include in the product template for all product that requires probing
near the potential wiper
John O'Connell 16-1-05
Template updated, design
procedure
8 1 5 40
Incorrect Circuit Layout
Incorrect Output 7 C Design Errors 7 PPAP sample
qualification 1 49 12/01/2005
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 7/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Design Functions & Requirements
Potential Failure Mode
Potential Effect(s) of
Failure
Sev
Class
Potential Cause(s) /
Mechanism(s) of Failure
Occur
Current Design Controls
Detect
RPN
Recommended Actions
Responsibility & Target
Completion Date
Actions Taken
Sev
Occ
Det
RPN
Termination Shorts circuit Erratic output 7 c Incorrect gap between tracks 7 Design Rules, PPAP,
Artwork Inspection 1 49
Short circuit Erratic output 7 c Incorrect Design 3 Design Rules, PPAP, Artwork Inspection 2 42
Resistor value drift Erratic gauge output 7 m Material unsuitable
for environment 5PPAP sample
qualification, customertests
2 70Reliability testing to be
carried out to verify material suitability
Tom Burke 2003/4Completed, Drift within
specification.7 4 2 56
Substrate Dimensions Parts not to sizeIncompatible
with customers assembly
8 M Design Errors 5
Drawing checked by Design Engineer,
PPAP Sample Qualification
1 40
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 8/29
PRODUCT PART APPROVAL PROCESS(PPAP)FMEA Number : PFM-C0003
FMEA Revision : Rev MECO No.: 05-0132
Prepared By : S P O'SullivanFMEA Date (Rev.) 22-Jun-05
Item Automotive Fuelcard Process Responsibility Bourns Ireland Mfg Eng FMEA Date (Orig.) 27-May-99Model 3714X-XXX-XXX Key Date : 22nd June 2005
Core Team M Delaney-Man, P Bradley - NPI,S.P.O'Sullivan - Qaulity,P Berry - Thickfilm Eng,EO'Regan - Prod Line Mgr
Process Functions & Requiremen
ts
Potential Failure Mode
Potential Effect(s) of
Failure
Sev
Class
Potential Cause(s) /
Mechanism(s) of Failure
Occur
Current Process Controls
Prevention
Current Process Controls Detection
Detect
RPN
Recommended Actions
Responsibility & Target
Completion Date
Actions Taken
Sev
Occ
Det
RPN
Receiving Inspection
Wrong material (Inks)
Yield impact/Line
down7 Supplier error/ No
testing at Incoming 2Certs of
Conformance / Supplier evaluation
3 42 N/A
Material shelf life expired/nearing
expiry
Yield impact/Line
down7 Supplier error 2
Receiving inspection/Operator
checks3 42 N/A
Slag too high Poor print definition 7 M Laser power settings 4
Print definition quality check. Bad batches returned to
laser Scribe.
2 56 N/A
Laser Scribe Scribe depth incorrect
Breakage problems 7 M Laser settings 1 Checks,SPC 1 7 N/A
Scribe position Inconsistent element sizes 6 M Laser programming 2 Check size at setup
at Laser Scribe 1 12 N/A
Laser Scribe Clean break on edge
Mis reg. On print. 7 M
Shallow scribe depth, worn breaker
block4 Visual check 8 224
Increase scribe depth,make Go/No Go
gauge PM on block, and gauge
Variance for scribe depth, to be ECO'd Pbe
Blocks to be implemented. MD
Complete 7 2 4 56
Print Top TermPrint defect -
Voids, Bridging, Blobs etc
Open Circuit/ Short Circuit 8 M Print settings 3 Visual, X-Ray Visual 8 192 Install & Commission
Vision detection system SPOS July 2005
Print Top term Wrong Ink used. Reliability issue 8 M Wrong ink selected. 4 Ink jar label, PO stating ink type 5 160
Templates filed by ink type, Segration of ink
types. Cross referance of lot numbers to COC's
in QA.
Mike D. July 16. Sean P. July 16 Completed 8 2 4 64
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 9/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Print Top term Ink thickness incorrect Reliability issue 8 M Wrong setup 2 Ink thickness
measuring machine Dektak 2 32
Templates filed by ink type, Segration of ink
types. Cross referance of lot numbers to COC's
in QA.
Mike D. July 16. Sean P. July 16 Completed 8 2 4 64
Print Top TermPrint defect - Voids, Bridging, Blobs etc
Open Circuit/ Short Circuit
8 M Design Problems 6 Design Rules 2 96Update design rules to
reflect actual print capability
JL; PB; EO'R; Customer. ECD Wk 26
2001Completed 8 4 2 64
8 M Screen problems 7 Visual 8 448
Add checks to Procedure. Change to 280 Mesh for screens. Verify effectiveness.
Add shorts / open tester
Procedures, Mesh PB, ECD Wk 28;
Effectivness, PB, ECD Wk 28; Tester, SPO'S,
ECD Wk 25 2001
Procedures / Mesh
change completed
8 4 2 64
Print alignmentOpen Circuit on part of wiper stroke
8 M Incorrect print setup 5 Visual 8 320Update procedures to
incorporate set up alignment checks
P.B. ECD Wk 13 2001 Procedure Updated 8 4 2 64
Dry & Fire top term Scratches of term Open Circuit/
Short Circuit 8 M Parts piling up at end of dryer 4 Visual & laser trim 5 160
Update procedure to scrap plates which pile
up.
Procedure PB, Wk 20, 2001 Data does not
support need for scraping plates, revised proceedure. Week 25
2002
Procedure Updated 8 4 1 32
Resist Print Resist Voids TR values out of spec 8 Mi Incorrect setup 3
TR setup check. Resistance check at
laser trim.1 24 N/A
Print misaligned Visual & Elect failure 7 M Incorrect setup 3 Visual & electrical
check at laser trim 2 42 N/A
Surface Treatment 1 Wiper Stiction 7 Procedure 4 112
Shortened lifetime 5 Routing 4 80
Reduced track thickness 5 Torque check 3 45
Debris on part 5 45
Smearing of ink 5 45
Broken plates 5 45
Surface Treatment process goes in-line.
Operating pressure too high
Pat Bradley 31st Sept 2005Operator ErrorMissed Process 4
Incorrect setup 3
Current check 3
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 10/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Wiper Stiction 7 Torque check 3 63
Shortened lifetime 5 Current check 3 45
Wiper Stiction 7 56
Shortened lifetime 5 40
Incorrect Active Element Contamination 5 Multiple materials in
stock 4 Stock only 1 material 3 60
Active Element Damage Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Contamination on tooling
Contaminated parts 5 No active cleaning 4 Air knife 3 60
Wrong plate orientation
Ink smearing/shorti
ng5 Operator error 3 Procedure/diagrams 3 45
Surface Treatment 2 Wiper Stiction 7 Procedure 4 112
Shortened lifetime 5 Routing 4 80
Reduced track thickness 5 Torque check 3 45
Debris on part 5 45
Smearing of ink 5 45
Broken plates 5 45
Wiper Stiction 7 Torque check 3 63
Shortened lifetime 5 Current check 3 45
Wiper Stiction 7 56
Shortened lifetime 5 40
Incorrect Active Element Contamination 5 Multiple materials in
stock 4 Stock only 1 material 3 60
Active Element Damage Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Contamination on tooling
Contaminated parts 5 No active cleaning 4 Air knife 3 60
Wrong plate orientation
Ink smearing/shorti
ng5 Operator error 3 Procedure/diagrams 3 45
Operating pressure too low Incorrect setup 3
Operating pressure too high
Worn Active Element
Active element wearing with use 4 PEMAC 2
3Current check
Incorrect setup 3
4
4Operator ErrorMissed Process
Incorrect setup 3Operating pressure too low
Worn Active Element
Active element wearing with use PEMAC 2
Surface Treatment process goes in-line.
Pat Bradley 31st Sept 2005
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 11/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Laser trim Untrimmed parts
Customer reject - can
cause end user failure
7 C Mishandling & m/c malfunction 5
Visual control & colour coded
storage of trimmed/untrimmed
parts
8 280 Install 100% autotester after laser Trim
WK, LC, TH, ECD - Week 25 2000
Eliminated requirement for colour code
racks.Week 15 2002
w 7 4 1 28
Dielectric Print, and Cure
Poorly Covered resist
Customer reject - can
cause end user failure
3 Mi Incorrect print set up. 3 Visual 8 72 n/A
Solder Stencil print, and wash
Poorly Covered term pad
Customer reject. 3 Mi Incorrect Stencil set
up 3 Visual 8 72 N/A
Poorly washed part
Customer reject, potential
corrosion7 Mi Incorrect
washing,check 5 Visual 8 280 Investigate potential for Corrosion Sean S.Week 05 Completed 1 4 7 28
Singulate into units Bad breaks
Customer cannot use
parts7 Mi Manual Breaking 5 Op - visual QA -
sample 8 280 Install breaker in shorts / open tester
TH, ECD - Week 25 2001 Completed 7 2 5 70
Machine dynamic test Shorts, Opens Customer
Issues 7 C Incorrect set up.Machine fault 3 Electrical test. 5 105
At set up 1 L/T failure to be taken, and tested to
verify failure
July 16 2003 Sean P., Mike D. Completed 7 3 1 21
Final Process Inspection No Inspection Customer
issues 7 C Poor training / Operator Error 3 Training/SDWT 2 42 n/A
Packing Wrong labels Shipment Return 7 Operator error 2
Inspecting 1 PO at a time. QA checks.
Op checks2 28 N/A
Wrong Qtys Customer dis-satisfaction 7 Operator Error 2
Inspecting 1 PO at a time. QA checks.
Op checks2 28 N/A
Mixed parts Customer dis-satisfaction 7 Operator Error 2
Inspecting 1 PO at a time. QA checks.
Op checks2 28 N/A
Final QA Inspection
Defective parts escaping
Customer complaints 7 Inspector error 2 QA Inspection 2 28 N/A
Shipping More than 1 P/N per box
Customer dis-satisfaction 5
Poor communication at shipping/packing
of customer requirement
4 Shipping checks 3 60 N/APPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 12/29
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 13/29
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 14/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
CCOONNTTRROOLL PPLLAANN // MMEEAASSUURREEMMEENNTT SSYYSSTTEEMM SSTTUUDDIIEESS
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 15/29
PRODUCT PART APPROVAL PROCESS (PPAP)
FUEL CARD PRE-LAUNCH CONTROL PLAN P ROTOTYPE PRE-LAUNCH PRODUCTION KEY CONTACT DATE ORIGINAL DATE REVISION
CONTROL PLAN NUMBER MCP-0002 Sean P. O’ Sullivan 02.09.2003 26.05.2005
PART NUMBER LATEST REVISION CORE TEAM CUSTOMER ENGINEERING APPROVAL DATE IF REQD 37XXX-XXX-XXX REV. B (ECO #05-0111) SPOS , Pat Bradley, Sean Sugrue ,Peter Berry PART NAME DESCRIPTION SUPPLIER/PLANT APPROVAL DATE CUSTOMER QUALITY APPROVAL DATE IF REQD
FUELCARD SUPPLIER/PLANT SUPPLIER CODE OTHER APPROVAL DATE (IF REQD) OTHER APPROVAL DATE IF REQD
BOURNS ELECTRONICS IRELAND
Process Flow Machine, Device,
Characteristics Methods Reaction if out-of-control
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
11
12
Receiving Inspection
N/A Ceramic Mfg Process
As per Certificate of Conformance, Visual& Dimensions
Appropriate part drawing as per BOM.
Micrometer, Tool Scope, Smart scope
See RP 003
Every ship- ment
Review C of C,Material history,Usage in production
Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.
21
22
Receiving Inspection
N/A Conductor Mfg process
As per Certificate of Conformance
C of C
Review Certificate of Conformance
N/A Every ship- ment
File C of C Comply to MM-C6015
Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.
31 32
Receiving Inspection
N/A Resist mfg Process
As per Certificate of Conformance
C of C
Review Certificate of Conformance
N/A Every ship- ment
File C of C Comply to MM-C6015
Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.
51
52
Screen Manufacture
Screen Stretcher & Exposure unit
Bourns Screen Manufacturing
Screen Blockage & shorts. Screen Tension.
TCPH3
Visual Inspection. Tensiometer.
All Screens
All Screens
Check vs TCPH3
Reject Screen
61 62
Receiving Inspection
N/A Shipping tray mfg process.
N/A – Ship to stock
Appropriate part drawing as per BOM.
N/A N/A Ship To stock
N/A Material rejected from floor On WIP. Reject material, impound and Identify with SCAR no. RTV.
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 16/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
150
150
160
160
Laser-Scribe Inspection
Laser Scribe
Camber guage C02 Laser scriber
Ceramic Mfg. Process Laser scribing
Camber Scribe depth
+
PS-C4000 PS-C4000
Camber Go / No Go guage Toolmakers Scope
5% of ship- ment 1 plate
Every ship- ment Every 100 plates
Log in L/S log book Log in MFG050 Pre-control SPC Chart (MFG217)
Inform Mfg. Engineer for dispositio Do not process with order. Green Zone = Normal production. White Zone = Continue but call Technician Red Zone = Stop and inform Supervisor.
Scribe Position PS-C4000 & Product Template
Toolmakers Scope At set up + start of every P.O. Record resultsOn MFG 050
See PS-C 4000
At setup And start of every P.O. Record results On MFG 050
Check Vs Product template
Re-check X+Y scribe m/c settings. If problem still exists call technician.
150
160
Laser Scribe C02 Laser scriber Laser scribing
Break out Dimension
+
Product template Vernier Calipers
30 Pieces,
6 Monthly.
Cpk >1.5. Calculate with SPC Kiss. Record results onNetwork server
Manufacturing Engineer to Review and decide on appropriate corrective action if required.
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 17/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method Ink Thickness
+
Limits as per layer Card SI-C-4193
Automated Vision system or X-ray machine
1 plate
At setupAnd Every 100 plates
Check results vs Layer Card, log on QA1000
At set-up- Change squeegee, Screen, check pressure - as required. In Process- Isolate product and inform Supervisor & Engineering Disposition : (a) Confirm product outside specification. (b) If outside specification scrap affected units
in order.
250 260 Term Print Screen Printer Screen Printing
Alignment & Gap Width
+
Product template Automated Vision systemOr shadow graph
1 plate
At setupAnd Every 100 plates
Check results Vs Product template Log on QA1000
Product template Smartscope 30 Pieces,6 gap measur-ements, 1 align-ment measu-rement.
Every 6 Months.
Cpk >1.5. Calculate with SPC Kiss. Record results on Network server
Manufacturing Engineer to Review and decide on appropriate corrective action if required.
270 280 Term Dry & fire Drier & furnace Drier & furnace
Settings / profile Thickness +
PS-C4088
Dektak Print Thickness
Meter 1 plate
Every 200
plates
Log Results on QA1000. Check vs
spec
Impound P.O. and inform engineering for disposition.
290 300 Visual Inspection
Mantis Inspection Station Visual inspection Visual Defects +
PS-C4088 Visual check
As per PS-
C4088
As per PS-
C4088
Check against PS-C4088,
Log rejects on plate.Units rejected.
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 18/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method 450
460 Mix Inks
& qualify Ink
Printer, drier, furnace & Furnace-room data-base / multimeter
Ink Mixing &
Ink qualification
Resistance
+
OP-4033C &
ME0032C
Furnace room data-base / Multimeter
As Per
Ink qual.
requirement
As Per
Ink qual.
requirement
Check program results vs TF
database
Re-blend & Re-qualify inks.
470 480 Resist Print Screen Printer Screen Printing Alignment +
Product Template Shadow graph 1 plate At set-up & every 100
plates
Record results on QA1000.
Check vs Template
Set-up = Reject if outside tolerance. Adjust printer and verify alignment within limits. In Process = Isolate product since last measurement, screen for out of spec product and scrap
490 500 Resist Dry & fire
Drier & furnace
Drier & Furnace settings /profile
Resistance +
PS-C4088 Furnace-room database &/ Multimeter
1 plate Every 100
plates
Log Results in Furnace-room database or on
MFG194, if D-Base is not available.
Inform Supervisor and Printing Operator. Disposition : (a) Supervisor to detemine
if Yield loss at Laser is acceptable. If Not Scrap entire order.
(b) Inform Ink Qual Operatorand retarget ink prior to processing further orders.
600 610 Surface Treatment 1
Surface treatmentmachine
Speed Motor Current Torque PS-C4232 Offline
Calibration 1 plate Weekly Fuelcard Torque Fixture
Inform Supervisor. Stop Brushing process till corrected.
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 19/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
800 810 Laser Trim Laser Trim Machine
Trimming TR Value Resistance C PS-C4197 Multimeter
5 trimmed
units
At set-up and every
30 mins
Check vs Laser Trim Database
Visually inspect laser cut to determine cause of problem. Check all parts back to last check. Mark rejects with marker.
PS-C4197 Trim Database 6 Monthly
Cpk > 1.66.
Review Cpk
results In trim
database.
Manufacturing Engineer to review and decide onappropriate correctivaction if required.
Set-up = Reject if outside tolerance. Adjust printer and verify alignment within limits. In Process = Isolate product since last measurement, screen for out of spec product and scrap
Laser Trim Laser Trim Machine
Finish quality
Kerf cleanliness and Position C PS-C4197
Microscope Vision System
5 trimmed
units
At set-up and every
30 mins
Visual Inspection
Determine cause of problem. Check all parts back to last check. Mark rejects with marker.
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 20/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
815 816 Solder print on pads
Stencil printer & Vitronics oven
Solder paste printing
Solder coverage and alignment
+
PS-C4219 PS-C4218 Visual 100% 100% Visual Check
Call a technician if coverage or alignment are not correct
820
830 Final Test TR Meter Final Test Resistance Value C Product Template
TR Meter
50 units 100% TR Test.
Notify NPI Program Manager Foe Eng. Analysis.
900 910
Final Inspection
N/A
Dimensional Checks
Dimensional
Product Template
Customer Drawing
Go / No Guage
Smartscope
50 units
2 units
100% 100%
Guage
Record results
Notify NPI Program Manager For Eng. Analysis Notify NPI Program Manager For Eng. Analysis
Final Inspection N/A Visual Visual defects
e.g. short-circuits As per Visual
Standards in MM-C6804
Visual Analysis 100% 100% Visual check
Reject batch and re-screen
Final Inspection N/A N/A Packaging &
Documentation MM-C6804 Visual As perMM-
C6804100% Visual check
Reject batch send for Screening.
920 930 Shipping N/A N/A Packaging & Documentation MM-C7026 Visual
As perMM-
C7026100% Visual check
Reject shipment, re-pack. Inform supervisor.
Special Characteristics Codes (Class)
C
Critical
+ Major (Significant)
_ Minor
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 21/29
Piece Part, Model, or Part Number: Division: Quarter & Year:
FUEL CARD Trimpot Q03 '05Measurement Systems Analysis Statistical Process Control Process Capability SPC CONTROL
Critical Characteristic Type & Model GR&R Date of Last Chart Sample Sample DOE FOR LAST 3 MONTHSand Specification of Gage % Mea. Study Type Size Frequency Cp Cpk Status
VISUAL AND DIMENSIONAL SMARTSCOPE 9.20% 29/06/2004 NONE NONE NONE n/a n/a n/a none none n/a VERIFICARIONSCRIBE DEPTH RHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 2.31 2.08 N/A IN IN IN0.010" +/-0.002 INCH SCOPE CHART 4 HRSSCRIBE DEPTH LHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 1.76 1.64 N/A IN IN IN0.010" +/-0.002 INCH SCOPE CHART 4 HRSTERM WIDTH (wet) BEI VISION 13.00% 27/09/2005 NONE 1 PLATE EVERY 100 1.73 1.18 N/A none none n/a.006'+/-.001 SYSTEM PLATES TERM THICKNESS DEKTAK 21.50% 29/06/2004 NONE 1.84 1.12 N/A none none n/a
TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 1.50 1.44 N/A none none n/aWIDTH (.016+/-.003 INCH) SYSTEM PLATESTERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 0.93 0.92 N/A none none n/aLENGTH (.010"+/-.003 INCH) SYSTEM PLATES
RESISTANCE MULTIMETER 0.20% 05/07/2004 NONE 2.90 1.68 n/a none none n/akiln pre trim HP34401aLASER TRIM MULTIMETER 8.60% 29/06/2004 NONE 3.13 2.74 N/A none none n/aRESISTANCE KEITHLEY 2010QA DIMENTIONAL VERNIER 15.95% 26/07/2005 NONE 2.09 1.62 N/A none none n/aLENGTH(38.1mm +0.25 /-0.05) MITUTOYO 500-191QA DIMENTIONAL VERNIER 17.72% 26/07/2005 NONE 2.37 1.33 N/A none none n/aWIDTH (16.40mm +.25/-.05) MITUTOYO 500-191QA DIMENTIONAL VERNIER 11.82% 29/06/2004 NONE 4.00 3.60 N/A none none n/aTHICKNESS (.63mm=/-.07mm) MITUTOYO 500-191
PRODUCTION PART APPROVAL PROCESS (PPAP)
PPAARRTT DDRRAAWWIINNGG && DDIIMMEENNSSIIOONNAALL RREEPPOORRTT
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 23/29
PRODUCTION PART APPROVAL - DIMENSIONAL RESULTS Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 BCustomer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM
Measurement Method : SmartscopeUnit 1 Unit 2 Unit 3 Unit 4 Unit 5
Item Nominal Tol + Tol - Units Min Max Special Actual OK Actual OK Actual OK Actual OK Actual OK
DIM1 35.9 0.10 -0.10 35.8958 35.9182 35.9179 35.9179 35.9182 35.9056 35.8958
DIM2 16 0.10 -0.10 15.9993 16.0097 16.0001 15.9998 15.9995 16.0097 15.9993DIM3 0.635 0.05 -0.05 0.6100 0.6200 0.6200 0.6200 0.6200 0.6100 0.6100DIM4 15.85 0.05 -0.05 15.8006 15.8618 15.8073 15.8096 15.8618 15.8006 15.8252DIM5 4.45 0.10 -0.10 4.3796 4.4544 4.4544 4.3836 4.3796 4.4085 4.4057DIM6 3 0.15 -0.15 2.9972 3.0282 2.9972 3.0048 3.0282 3.0044 3.0055DIM7 5 0.15 -0.15 4.9931 5.0386 4.9931 5.0130 5.0386 5.0005 5.0311DIM8 0.3 0.10 -0.10 0.8164 0.8216 0.8191 0.8174 0.8164 0.8216 0.8194DIM9 14.5 0.20 -0.20 14.5069 14.5475 14.5475 14.5069 14.5220 14.5117 14.5309
DIM10 16.5 0.05 -0.05 16.5414 16.5472 16.5472 16.5436 16.5414 16.5447 16.5444DIM11 18.5 0.25 -0.25 18.4795 18.5144 18.5144 18.4795 18.4934 18.4920 18.5043DIM12 2.9 0.10 -0.10 2.8466 2.9076 2.8618 2.8581 2.9076 2.8466 2.8581DIM13 5.85 0.15 -0.15 5.8601 5.9043 5.8601 5.8882 5.9043 5.8789 5.8887DIM14 53.19 0.50 -0.50 53.5253 53.6889 53.6889 53.5253 53.6193 53.6134 53.5282DIM15 56.19 0.50 -0.50 56.2135 56.3012 56.3012 56.2245 56.2135 56.2358 56.2272DIM16 73.87 0.50 -0.50 73.8953 73.9500 73.9500 73.9241 73.8977 73.9106 73.8953DIM17 89.02 0.50 -0.50 89.0379 89.0938 89.0749 89.0938 89.0621 89.0604 89.0379DIM18 104.45 0.50 -0.50 104.4698 104.5508 104.5065 104.5508 104.4941 104.5221 104.4698DIM19 109.9 0.50 -0.50 109.9144 109.9994 109.9399 109.9994 109.9605 109.9684 109.9144DIM20 122.42 0.50 -0.50 122.4417 122.5419 122.4500 122.5419 122.4979 122.5010 122.4417DIM21 126 0.50 -0.50 126.2407 126.4399 126.2786 126.4399 126.2407 126.3801 126.3533
PRODUCTION PART APPROVAL PROCESS (PPAP)
RREESSIISSTTAANNCCEE MMEEAASSUURREEMMEENNTT RREEPPOORRTT
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 24/29
Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 BCustomer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM
Measurement Method : Keithley MultimeterRST.# R1 R2 R3 R4 R5 R6 R7 R8NOM. TR. Ω 2.00 5.00 17.00 32.50 50.00 70.00 120.00 125.00Tolerance + 0.50 0.50 0.50 0.50 0.50 0.70 1.20 1.25Tolerance - -0.50 -0.50 -0.50 -0.50 -0.50 -0.70 -1.20 -1.25
1 1.9571 5.0455 16.958 32.466 49.961 69.935 120.03 1252 1.9586 4.9708 16.975 32.454 49.964 69.911 120.03 125.033 1.9641 5.1183 16.969 32.454 49.98 69.916 120.04 125.074 1.9654 5.1171 16.964 32.464 49.981 69.98 120.1 125.075 1.9668 4.9605 16.968 32.469 49.979 69.901 120 125.016 2.0146 5.0553 16.989 32.493 50.032 69.955 120.07 125.057 1.9978 5.1506 16.991 32.497 50.008 69.97 120.07 125.068 1.9961 5.0464 17.011 32.502 50.018 69.969 120.13 125.079 1.996 5.0308 17 32.484 50.074 69.94 120.07 125.07
10 2.0174 5.0305 17.009 32.52 50.027 69.999 120.09 125.0911 1.9954 5.1542 16.997 32.504 50.012 69.977 120.09 125.0412 2.001 5.0454 16.994 32.503 50.015 69.949 120.08 125.0613 1.9976 5.0098 17.002 32.493 50.013 70.031 120.06 125.0114 1.9979 5.0602 17.001 32.514 50.021 69.942 120.08 125.0915 1.9835 5.0899 16.987 32.511 50.003 69.994 120.08 125.1116 2.0091 5.0402 17.003 32.502 49.99 69.955 120.14 125.1217 1.9934 5.1129 17.009 32.5 50.012 69.949 120.1 125.118 1.9944 5.1028 17.001 32.499 50.012 69.947 120.09 125.0919 2.0045 5.031 17.002 32.498 49.982 69.975 120.03 125.0420 1.9859 5.0445 16.988 32.496 49.994 70 120.09 125.121 1.9793 4.9934 16.984 32.487 50.007 69.893 120.04 125.0122 1.9756 5.0825 16.98 32.48 49.991 69.963 120.1 125.1123 1.966 4.9686 16.984 32.489 49.977 69.965 120.04 125.0324 1.961 5.0874 16.977 32.469 49.978 69.947 120.07 125.0925 1.9652 4.9777 16.974 32.491 49.981 69.924 120.08 125.0426 2.0004 5.1785 16.995 32.491 50.004 69.959 120.01 125.0227 1.9807 5.0044 16.997 32.485 50.003 69.965 120.04 125.0328 1.9805 5.1058 17.002 32.506 49.995 69.959 120.1 125.0729 1.9871 5.0871 16.983 32.501 50.005 69.974 120.09 125.0830 2.0017 5.0724 16.992 32.498 50.006 69.923 120.11 125.0731 1.9915 4.9903 16.993 32.497 50.005 69.954 120.07 125.0532 1.9876 5.1488 16.998 32.501 50.008 69.949 120.15 125.0833 1.9712 4.9906 16.99 32.484 49.99 69.943 120.07 125.0734 1.9749 4.9797 16.983 32.477 49.985 69.961 120.1 125.135 1.981 5.0072 16.986 32.484 49.985 69.935 120.13 125.0736 1.9918 5.1638 16.983 32.492 50.019 69.94 120.1 125.0737 1.9996 5.0066 16.992 32.501 50.005 69.993 120.06 125.0738 1.9733 5.0317 17.004 32.501 50.021 70.005 120.13 125.0939 1.9723 5.1322 16.985 32.47 50.022 69.943 120.09 125.0640 1.9928 5.1354 16.999 32.481 49.998 69.941 120.05 125.0341 2.2248 5.2413 17.203 32.689 50.208 70.169 120.3 125.2942 2.2009 5.2474 17.193 32.693 50.204 70.156 120.24 125.2243 2.1958 5.2742 17.193 32.705 50.213 70.122 120.27 125.2944 2.2068 5.2529 17.202 32.709 50.23 70.153 120.34 125.3145 2.2201 5.2914 17.223 32.718 50.215 70.257 120.29 125.2846 1.9753 5.0116 16.986 32.488 49.997 69.887 120.07 125.0247 1.9717 5.0925 16.971 32.5 49.986 69.962 120.09 125.0648 1.982 5.0394 16.987 32.481 49.988 70.116 120.04 125.0249 1.9775 5.021 16.968 32.484 49.98 69.939 120.05 125.0350 1.9794 5.1157 16.991 32.476 50.018 69.957 120.11 125.06
MEAN 2.01 5.08 17.01 32.51 50.02 69.98 120.10 125.08Std. Dev. 0.07 0.08 0.07 0.07 0.07 0.08 0.07 0.07
Max. 2.22 5.29 17.22 32.72 50.23 70.26 120.34 125.31Min. 1.96 4.96 16.96 32.45 49.96 69.89 120.00 125.00
Cm 2.39 2.00 2.52 2.52 2.47 3.09 5.53 5.72Cmk 2.36 1.68 2.47 2.46 2.36 3.00 5.08 5.35
NAME: Caroline Hickey DATE: 10/11/2005
PRODUCTION PART APPROVAL PROCESS (PPAP)
MMAATTEERRIIAALL CCEERRTTIIFFIICCAATTIIOONN && IIMMDDSS AAPPPPRROOVVAALL
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 25/29
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 26/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
AAPPPPEEAARRAANNCCEE AAPPPPRROOVVAALL RREEPPOORRTT && PPAACCKKAAGGIINNGG DDEESSCCRRIIPPTTIIOONN
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 28/29
PART NO.
SUPPLIER NAMEIRL
SUPPLIER CODE DSZ QA
PASS FAIL
CUSTOMER REPRESENTATIVE SIGNATURE DATE
MARK MARTIN
INSPECTED BY TELEPHONE NO.
00353 21 4515 381
OTHER
COMMENT
CUSTOMER USE ONLY
CONTAMINATION
DRAWING NO.
Fuelcard Appearance Approval Report
BOURNS ELECTRONICSMANUFACTURING LOCATION
BLISTERS
SCRATCHES
MARKINGS
JAGGED EDGES
VOIDS
PROTRUSIONS
SOLDER COVERAGE
DEFECT DESCRIPTION
CAROLINE HICKEY
SMEARS/SMUDGES
OPEN CIRCUITS
SHORTS
PPAP DOCUMENT NO.:0009-PECO No.:05-0168 BOURNS ELECTRONICS IRELAND 29/29