Ppap Sample Documents

PRODUCTION PART APPROVAL PROCESS (PPAP)

Supplier Name/Location/Supplier Code: Bourns Electronics Ireland Mahon Industrial Estate Blackrock Cork Ireland

Supplier Part Number:

Customer part number

583 242 99 Part/Family Description:

FUELCARD Submission Date:

23/11/2005

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

1/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

CONTENTS TS16949 CERTIFICATION PART SUBMISSION WARRANT DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART CONTROL PLAN / MEASUREMENT SYSTEM STUDIES PART DRAWING & DIMENSIONAL REPORT RESISTANCE MEASUREMENT REPORT MATERIAL CERTIFICATION & IMDS APPROVAL APPEARANCE REPORT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

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PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

3/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

PART SUBMISSION WARRANT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

4/29

Part Submission Warrant 3714X-BFY-000

Bourns Part Number Safety and/or Government Regulation

Yes

No

583 242 99

Customer Part Number

Engineering Drawing Change Level

C

NONE

Additional Engineering Changes

Purchase Order No.

SUPPLIER MANUFACTURING INFORMATION

SUBMISSION INFORMATION Dimensional

MAHON INDUSTRIAL ESTATE Street Address

10/17/2005

Dated

N/A

70014346

Shown on Drawing Number

BOURNS ELECTRONICS Supplier Name

Dated

Materials/Function

Appearance

PRICOL

Customer Name/Division

BLACKROCK CORK City

State

Note:

Zip

Has this part been reported in IMDS (or equivalent)?

No

Yes

REASON FOR SUBMISSION ✔

Initial submission

Change to Optional Construction or Material

Engineering Change's)

Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional

Change in Part Processing

Correction of Discrepancy

Parts produced at Additional Location

Tooling Inactive > than 1 year

Last PSW > 1 year old Other - please specify

REQUESTED 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 RESULTS The results for

dimensional measurements

material and functional tests

These results meet all drawing and specification requirements:

appearance criteria

YES

NO

statistical process package

(If "NO" - Explanation Required)

DECLARATION I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements.

QTY 100 QTY 100

EXPLANATION/COMMENTS: Print Name

Title

Sample co ordinator

Phone No.

Supplier Authorized Signature

00353 21 4515 381

Date

Fax No. 00353 21 4515 292

10/11/2005

Supplier E-mail Address FOR CUSTOMER USE ONLY (IF APPLICABLE) Part Warrant Disposition:

Customer Name

Approved

Rejected

Customer Signature

uantities until functional approval or waiver is PPAP DOCUMENT NO.:0009-P ECO No.:05-0168 BOURNS ELECTRONICS IRELAND om customer.

Date

5/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

6/29

PRODUCT PART APPROVAL PROCESS(PPAP)

Bourns Electronics (Irl)

FMEA Number : FMEA Revision :

Failure Mode & Effects Analysis Item : Automotive Fuel Level Sensor Model :3710X-XXX, 3714X-XXX Core Team : JL, MO'B, SPOS, PB, EO'R

Prepared By : FMEA Date (Rev.) FMEA Date (Orig.) D e t e c t

R P N

Design Functions & Requirements

Potential Failure Mode

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

PPAP sample 5 qualification, customer 2 tests

60

Open circuit

No gauge reading

8

C

Incorrect Design

Design Rules, PPAP, Gerber View, Artwork 1 Inspection

40

Open circuit

No gauge reading

8

C

Probe mark on resistor card.

Eratic opencircuit

8

Positioning of probe C points on wiper travel 4 area.

Incorrect Circuit Layout

Incorrect Output

7

C

Termination

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

5

Incorrect material selection, Premature 2 element wear

Design Errors

7

PPAP sample qualification

Rev G

ECO No.: 05-0046

Design FMEA

O C Potential Potential S c l Cause(s) / Current Design Effect(s) of e c a Mechanism(s) Controls Failure v u s of Failure r s

DFM-C0002

2

S P O'Sullivan 21-Feb-05 01-Aug-96

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

S O D e c e v c t

R P N

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

40

32

Not listed.

5

160

PPAP sample qualification

1

49

BOURNS ELECTRONICS IRELAND

1

12/01/2005

7/29

5

PRODUCT PART APPROVAL PROCESS(PPAP) O C Potential Potential S c l Cause(s) / Current Design Effect(s) of e c a Mechanism(s) Controls Failure v u s of Failure r s

D e t e c t

R P N

Design Functions & Requirements

Potential Failure Mode

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

PPAP sample 5 qualification, customer 2 tests

70

Design Errors

Drawing checked by Design Engineer, PPAP Sample Qualification

40

Substrate Dimensions

Parts not to size

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Incompatible with customers 8 assembly

M

5

1

BOURNS ELECTRONICS IRELAND

Recommended Actions

Responsibility & Target Completion Date

Actions Taken

Reliability testing to be carried out to verify material suitability

Tom Burke 2003/4

Completed, Drift within specification.

S O D e c e v c t

R P N

7

56

4

8/29

2

PRODUCT PART APPROVAL PROCESS(PPAP) FMEA Number : FMEA Revision : ECO No.: Prepared By : FMEA Date (Rev.) FMEA Date (Orig.)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA) Item Automotive Fuelcard Process Responsibility Bourns Ireland Mfg Eng Model 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 C Potential Process Potential S l Cause(s) / Functions & Potential Effect(s) of e a Mechanism(s) Requiremen Failure Mode Failure v s of Failure ts s

D e t e c t

R P N

Recommended Actions

Certs of Conformance / Supplier evaluation

3

42

N/A

Receiving 2 inspection/Operator checks

3

42

N/A

Print definition quality check. Bad batches returned to laser Scribe.

2

56

N/A

1

Checks,SPC

1

7

N/A

2

Check size at setup at Laser Scribe

1

12

N/A

O c c u r

Current Process Controls Prevention

2

Wrong material (Inks)

Yield impact/Line down

7

Supplier error/ No testing at Incoming

Material shelf life expired/nearing expiry

Yield impact/Line down

7

Supplier error

Slag too high

Poor print definition

7

M Laser power settings 4

Scribe depth incorrect

Breakage problems

7

M

Scribe position

Inconsistent element sizes

6

M Laser programming

Laser Scribe

Clean break on edge

Mis reg. On print.

7

Shallow scribe M depth, worn breaker 4 block

Visual check

Print Top Term

Print defect Voids, Bridging, Blobs etc

Open Circuit/ Short Circuit

8

M

Visual, X-Ray

Receiving Inspection

Laser Scribe

Print Top term

Wrong Ink used. Reliability issue 8

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Laser settings

Print settings

M Wrong ink selected.

3

4

Current Process Controls Detection

Visual

Ink jar label, PO stating ink type BOURNS ELECTRONICS IRELAND

PFM-C0003 Rev M 05-0132 S P O'Sullivan 22-Jun-05 27-May-99

Responsibility & Target Completion Date

8

224

Increase scribe Variance for scribe depth,make Go/No Go depth, to be ECO'd Pbe gauge PM on block, Blocks to be and gauge implemented. MD

8

192

Install & Commission Vision detection system

SPOS July 2005

5

Templates filed by ink type, Segration of ink 160 types. Cross referance of lot numbers to COC's in QA.

Mike D. July 16. Sean P. July 16

Actions Taken

S O D e c e v c t

R P N

Complete

7

2

4

56

Completed

8

2

4

64

9/29

PRODUCT PART APPROVAL PROCESS(PPAP)

Print Top term

Ink thickness incorrect

Print defect Print Top Term Voids, Bridging, Blobs etc

Reliability issue 8

M

Wrong setup

2

Ink thickness measuring machine

Open Circuit/ Short Circuit

M

Design Problems

6

Design Rules

8

8

Print alignment

Open Circuit on part of wiper 8 stroke

M

Screen problems

M Incorrect print setup

4

2

64

4

2

64

5

160

1

24

N/A

Visual & electrical check at laser trim

2

42

N/A

Procedure

4

112

Routing

4

80

3

45

Mi

Incorrect setup

TR setup check. 3 Resistance check at laser trim.

Print misaligned

Visual & Elect failure

7

M

Incorrect setup

3

Wiper Stiction

7 Operator Error

4

5

8

Procedure PB, Wk 20, 2001 Data does not Update procedure to support need for scrap plates which pile scraping plates, revised up. proceedure. Week 25 2002

8

5

Completed

Update procedures to incorporate set up alignment checks

TR values out of spec

4

Visual & laser trim

Torque check Incorrect setup

64

320

Resist Voids

5

4

8

Resist Print

Operating Debris on part pressure too high Smearing of ink PPAP DOCUMENT NO.:0009-P Broken plates ECO No.:05-0168

2

Visual

Parts piling up at end of dryer

5

Update design rules to JL; PB; EO'R; reflect actual print Customer. ECD Wk 26 capability 2001

8

5

M

Reduced track thickness

96

Completed

8

8

5

2

Mike D. July 16. Sean P. July 16

Visual

Open Circuit/ Short Circuit

Shortened lifetime

32

7

Scratches of term

Missed Process

2

Add checks to Procedures, Mesh PB, Procedures / Procedure. Change to ECD Wk 28; Mesh 448 280 Mesh for screens. Effectivness, PB, ECD 8 change Verify effectiveness. Wk 28; Tester, SPO'S, completed Add shorts / open tester ECD Wk 25 2001

Dry & Fire top term

Surface Treatment 1

Dektak

Templates filed by ink type, Segration of ink types. Cross referance of lot numbers to COC's in QA.

3

Surface Treatment process goes in-line.

P.B. ECD Wk 13 2001

Procedure Updated

8

4

2

64

Procedure Updated

8

4

1

32

Pat Bradley 31st Sept 2005

45 Current check

BOURNS ELECTRONICS IRELAND

3

45 45

10/29

PRODUCT PART APPROVAL PROCESS(PPAP) Operating pressure too low

Worn Active Element

Wiper Stiction

Surface Treatment 2

Shortened lifetime

5

Wiper Stiction

7

Shortened lifetime

Operating pressure too low

Worn Active Element

45

PEMAC

2

56

4

Stock only 1 material

3

60

7

Lack of inspection

3

PEMAC

2

42

5

No active cleaning

4

Air knife

3

60

3

45

Procedure

4

112

Routing

4

80

3

45

40

Operator error

3 Procedure/diagrams

Operator Error

4

7

5 5

Torque check Incorrect setup

3 3

5

5

Wiper Stiction

7

45

Torque check

3

63

Current check

3

45

PEMAC

2

3

56

Active element wearing with use

4

5

Multiple materials in stock

4

Stock only 1 material

3

60

7

Lack of inspection

3

PEMAC

2

42

5

No active cleaning

4

Air knife

3

60

3

45

5

Ink Wrong plate smearing/shorti 5 orientation NO.:0009-P PPAP DOCUMENT ng ECO No.:05-0168

Pat Bradley 31st Sept 2005

45

7

Shortened lifetime

Surface Treatment process goes in-line.

45 Current check

5

Incorrect setup

Incorrect Active Contamination Element Active Element Wiper Stiction Damage Contamination on Contaminated tooling parts

3

Multiple materials in stock

Reduced track thickness

Shortened lifetime

Current check

5

5

5

Wiper Stiction

63

4

Shortened lifetime

Operating Debris on part pressure too high Smearing of ink Broken plates

3

3

Active element wearing with use

Ink smearing/shorti 5 ng Wiper Stiction

Missed Process

Torque check Incorrect setup

Incorrect Active Contamination Element Active Element Wiper Stiction Damage Contamination on Contaminated tooling parts Wrong plate orientation

7

Operator error

40

3 Procedure/diagrams BOURNS ELECTRONICS IRELAND

11/29

PRODUCT PART APPROVAL PROCESS(PPAP)

Laser trim

Mishandling & m/c malfunction

Visual control & colour coded 5 storage of trimmed/untrimmed parts

8

280

Mi

Incorrect print set up.

3

Visual

8

72

n/A

3

Mi

Incorrect Stencil set up

3

Visual

8

72

N/A

Customer reject, potential 7 corrosion

Mi

Incorrect washing,check

5

Visual

8

280

Investigate potential for Corrosion

Customer reject - can Untrimmed parts 7 cause end user failure

C

Customer reject - can 3 cause end user failure

Dielectric Print, and Cure

Poorly Covered resist

Solder Stencil print, and wash

Poorly Covered term pad

Poorly washed part

Customer reject.

WK, LC, TH, ECD Week 25 2000 Install 100% autotester Eliminated requirement after laser Trim for colour code racks.Week 15 2002

w

7

4

1

28

Sean S.Week 05

Completed

1

4

7

28

TH, ECD - Week 25 2001

Completed

7

2

5

70

Completed

7

3

1

21

Singulate into units

Bad breaks

Customer cannot use parts

7

Mi

Manual Breaking

5

Op - visual QA sample

8

280

Install breaker in shorts / open tester

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 July 16 2003 Sean P., be taken, and tested to Mike D. verify failure

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 checks

2

28

N/A

Wrong Qtys

Customer dissatisfaction

7

Operator Error

2

Inspecting 1 PO at a time. QA checks. Op checks

2

28

N/A

Mixed parts

Customer dissatisfaction

7

Operator Error

2

Inspecting 1 PO at a time. QA checks. Op checks

2

28

N/A

Defective parts escaping

Customer complaints

7

Inspector error

2

QA Inspection

2

28

N/A

Shipping checks

3

60

N/A

Final QA Inspection

More than 1 P/N Customer disShipping per box satisfaction PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

5

Poor communication at shipping/packing 4 of customer requirement

BOURNS ELECTRONICS IRELAND

12/29

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

13/29

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

14/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

CONTROL PLAN / MEASUREMENT SYSTEM STUDIES

PPAP DOCUMENT NO.:0009-P ECO 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 26.05.2005

CONTROL PLAN NUMBER

MCP-0002

Sean P. O’ Sullivan

02.09.2003

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

OTHER APPROVAL DATE (IF REQD)

OTHER APPROVAL DATE IF REQD

FUELCARD SUPPLIER/PLANT

SUPPLIER CODE

BOURNS ELECTRONICS IRELAND Process Flow No.

Machine, Device, Jigs, Tools for Manufacturing

Characteristics

Check

Process Name

12

Receiving Inspection

N/A

11

Ceramic Mfg Process

21

22

Receiving Inspection

N/A

32

Receiving Inspection

N/A

31 51

52

Screen Manufacture

Process

61

62

Receiving Inspection

Process Parameters

Methods

Product Characteristics

Product/Process Specification

Measurement Method

As per Certificate of Conformance, Visual & Dimensions

Appropriate part drawing as per BOM.

Micrometer, Tool Scope, Smart scope

See RP 003

Every shipment

Review C of C, Reject material, impound and Material history, Identify with SCAR no. RTV as per OP-C6007. Usage in production

Conductor Mfg process

As per Certificate of Conformance

C of C

Review Certificate of Conformance

N/A

Every shipment

File C of C Comply to MM-C6015

Reject material, impound and Identify with SCAR no. RTV as per OP-C6007.

Resist mfg Process

As per Certificate of Conformance

Review Certificate of Conformance Visual Inspection. Tensiometer.

N/A

Every shipment All All Screens Screens

File C of C Comply to MM-C6015 Check vs TCPH3

Reject material, impound and Identify with SCAR no. RTV as per OP-C6007. Reject Screen

N/A

N/A

N/A

Material rejected from floor On WIP. Reject material, impound and Identify with SCAR no. RTV.

Bourns Screen Screen Manufacturing Stretcher & Exposure unit

Screen Blockage & shorts. Screen Tension.

N/A

N/A – Ship to stock

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Shipping tray mfg process.

Class

Reaction if out-of-control

C of C

TCPH3 Appropriate part drawing as per BOM.

BOURNS ELECTRONICS IRELAND

Sample Size Freq.

Ship To stock

Analysis Method

Conditions are encountered

16/29

PRODUCT PART APPROVAL PROCESS (PPAP) Process Flow No. Process Process Check Name

Machine, Device, Jigs, Tools for Manufacturing

Characteristics Process Product Parameters Characteristics

150

160

Laser-Scribe Inspection

Camber guage

Ceramic Mfg. Process

Camber

150

160

Laser Scribe

C02 Laser scriber

Laser scribing

Scribe depth

Class

Product/Process Specification

Methods Measurement Sample Method Size Freq.

Analysis Method

PS-C4000

Camber Go / No Go guage

5% of shipment

Every shipment

Log in L/S log book

PS-C4000

Toolmakers Scope

1 plate

Every 100 plates

Log in MFG050

Reaction if out-of-control Conditions are encountered

Inform Mfg. Engineer for dispositio

Do not process with order.

150

160

Laser Scribe

C02 Laser scriber

Laser scribing

+

Scribe Position

PS-C4000 & Product Template

Toolmakers Scope At set up + start of every P.O. Record results On MFG 050

See PS-C 4000

Product template

Vernier Calipers

30 Pieces,

+ Break out Dimension

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

At setup And start of every P.O. Record results On MFG 050 6 Monthly.

Green Zone = Normal production. White Zone = Continue but call Technician Red Zone = Stop and inform Supervisor. Check Vs Re-check X+Y scribe m/c Product template settings. If problem still exists call technician. Pre-control SPC Chart (MFG217)

Cpk >1.5. Calculate with SPC Kiss. Record results on Network server

Manufacturing Engineer to Review and decide on appropriate corrective action if required.

17/29

PRODUCT PART APPROVAL PROCESS (PPAP) Process Flow No. Process Process Check Name

Machine, Device, Jigs, Tools for Manufacturing

250

Screen Printer

260

Term Print

Characteristics Process Product Parameters Characteristics Screen Printing

Class

Product/Process Specification Limits as per layer Card SI-C-4193

Ink Thickness

Methods Measurement Sample Method Size Freq.

1 plate

At setup Check results vs Layer Card, And log on QA1000 Every 100 plates

1 plate

At setup Check results Vs Product template And Log on QA1000 Every 100 plates

Automated Vision system or

+

Analysis Method

X-ray machine

Alignment & Gap Width

Product template

Automated Vision system Or shadow graph

Reaction if out-of-control Conditions are encountered 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.

+

Product template

270

280

Term Dry & fire

290

300

Visual Inspection

Drier & furnace

Drier & furnace Settings / profile

Mantis Inspection Visual inspection Station

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Thickness

+

Visual Defects

+

Smartscope

Every 30 Pieces, 6 Months. 6 gap measurements, 1 alignment measurement.

PS-C4088

Dektak Print Thickness Meter

1 plate

Every 200 plates

PS-C4088

Visual check

As per PSC4088

As per PSC4088

BOURNS ELECTRONICS IRELAND

Cpk >1.5. Calculate with SPC Kiss. Record results on Network server

Log Results on QA1000. Check vs spec

Manufacturing Engineer to Review and decide on appropriate corrective action if required.

Impound P.O. and inform engineering for disposition.

Check against PS-C4088, Units rejected. Log rejects on plate.

18/29

PRODUCT PART APPROVAL PROCESS (PPAP) Process Flow No. Process Process Check Name 450

470

460

480

Mix Inks & qualify Ink

Resist Print

Machine, Device, Jigs, Tools for Manufacturing Printer, drier, furnace & Furnace-room data-base / multimeter

Screen Printer

Characteristics Process Product Parameters Characteristics Ink Mixing & Ink qualification

Class

Resistance

Product/Process Specification

Methods Measurement Sample Method Size Freq.

OP-4033C & ME0032C

Furnace room data-base / Multimeter

Product Template

As Per Ink qual. require ment

As Per Ink qual. require ment

Shadow graph

1 plate

At setup & every 100 plates

Furnace-room database &/ Multimeter

1 plate

Every 100 plates

Offline Calibration

1 plate

Weekly

+

Screen Printing

Alignment

+

490

500

600

610

Resist Dry & fire

Drier & furnace

Surface Surface treatment Treatment 1 machine

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Drier & Furnace settings /profile

Speed Motor Current

Resistance

Torque

+

PS-C4088

PS-C4232

BOURNS ELECTRONICS IRELAND

Analysis Method

Check program results vs TF database

Reaction if out-of-control Conditions are encountered

Re-blend & Re-qualify inks.

Record results on Set-up = Reject if outside tolerance. Adjust printer and QA1000. Check vs Template verify alignment within limits. In Process = Isolate product since last measurement, screen for out of spec product and scrap Inform Supervisor and Printing Operator. Disposition : (a) Supervisor to detemine if Yield loss at Laser is acceptable. If Not Scrap entire order. Log Results in (b) Inform Ink Qual Operator Furnace-room and retarget ink prior to database or on processing further MFG194, if D-Base orders. is not available.

Fuelcard Torque Fixture

Inform Supervisor. Stop Brushing process till corrected.

19/29

PRODUCT PART APPROVAL PROCESS (PPAP) Process Flow No. Process Process Check Name

800

810

Laser Trim

Machine, Device, Jigs, Tools for Manufacturing

Laser Trim Machine

Characteristics Process Product Parameters Characteristics

Trimming TR Value

Resistance

Class

C

Product/Process Specification

PS-C4197

PS-C4197

Laser Trim

Laser Trim Machine

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

Finish quality

Kerf cleanliness and Position

C

Methods Measurement Sample Method Size Freq.

PS-C4197

Multimeter

5 trimmed units

At setup and Check vs Laser every Trim Database 30 mins

Cpk > 1.66. Review Cpk 6 Trim Database Monthly results In trim databas e.

At setup and 5 Microscope trimmed every Vision System 30 mins units

BOURNS ELECTRONICS IRELAND

Analysis Method

Manufacturing Engineer to review and decide on appropriate correctiv action if required.

Visual Inspection

Reaction if out-of-control Conditions are encountered

Visually inspect laser cut to determine cause of problem. Check all parts back to last check. Mark rejects with marker. 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

Determine cause of problem. Check all parts back to last check. Mark rejects with marker.

20/29

PRODUCT PART APPROVAL PROCESS (PPAP) Process Flow No. Process Process Check Name

Machine, Device, Jigs, Tools for Manufacturing

Characteristics Process Product Parameters Characteristics

Class

Product/Process Specification

Methods Measurement Sample Method Size Freq.

Analysis Method

Reaction if out-of-control Conditions are encountered

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.

Final Inspection

N/A

Dimensional Checks

Dimensional

Guage

Notify NPI Program Manager For Eng. Analysis

900

910

Product Template

Go / No Guage

Customer Drawing

920

930

Smartscope

Final Inspection

N/A

Visual

Visual defects e.g. short-circuits

As per Visual Standards in MM-C6804

Visual Analysis

Final Inspection

N/A

N/A

Packaging & Documentation

MM-C6804

Visual

Shipping

N/A

N/A

Packaging & Documentation

MM-C7026

Visual

50 units 100% 2 units

100%

Record results

Notify NPI Program Manager For Eng. Analysis Reject batch and re-screen

100% As per MMC6804 As per MMC7026

100%

Visual check

100%

Visual check

Reject batch send for Screening.

100%

Visual check

Reject shipment, re-pack. Inform supervisor.

Special Characteristics Codes (Class) C

Critical

+

Major (Significant)

_

Minor

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

21/29

Piece Part, Model, or Part Number:

FUEL CARD Critical Characteristic and Specification VISUAL AND DIMENSIONAL VERIFICARION SCRIBE DEPTH RHS 0.010" +/-0.002 INCH SCRIBE DEPTH LHS 0.010" +/-0.002 INCH TERM WIDTH (wet) .006'+/-.001 TERM THICKNESS TERM ALIGNMENT WIDTH (.016+/-.003 INCH) TERM ALIGNMENT LENGTH (.010"+/-.003 INCH) RESISTANCE kiln pre trim LASER TRIM RESISTANCE QA DIMENTIONAL LENGTH(38.1mm +0.25 /-0.05) QA DIMENTIONAL WIDTH (16.40mm +.25/-.05) QA DIMENTIONAL THICKNESS (.63mm=/-.07mm)

Division:

Quarter & Year:

Trimpot Measurement Systems Analysis

Q03 '05 Statistical Process Control Sample

Sample

Type

Size

Frequency

NONE

NONE

NONE

Process Capability SPC CONTROL DOE FOR LAST 3 MONTHS Cp Cpk Status n/a n/a n/a none none n/a

5 PIECES

EVERY

2.31

2.08

N/A IN

IN

IN

1.76

1.64

N/A IN

IN

IN

1.73

1.18

N/A none

none

n/a

1.84

1.12

N/A none

none

n/a

1.50

1.44

N/A none

none

n/a

0.93

0.92

N/A none

none

n/a

Type & Model

GR&R

Date of Last

of Gage

% 9.20%

Mea. Study

29/06/2004

15.35%

10/02/2005

X/R

SMARTSCOPE TOOLMAKERS SCOPE TOOLMAKERS SCOPE BEI VISION SYSTEM DEKTAK BEI VISION SYSTEM BEI VISION SYSTEM MULTIMETER HP34401a MULTIMETER KEITHLEY 2010 VERNIER MITUTOYO 500-191 VERNIER MITUTOYO 500-191 VERNIER MITUTOYO 500-191

Chart

CHART

15.35%

10/02/2005

X/R

4 HRS 5 PIECES

CHART

27/09/2005

NONE

21.50% 29/06/2004

NONE

5.50% 06/07/2005

NONE

13.00%

EVERY 4 HRS

1 PLATE

EVERY 100 PLATES

1 PLATE

EVERY 100 PLATES

5.50% 06/07/2005

NONE

1 PLATE

EVERY 100 PLATES

0.20% 05/07/2004

NONE

2.90

1.68

n/a none none n/a

8.60% 29/06/2004

NONE

3.13

2.74

N/A none

none

n/a

15.95% 26/07/2005

NONE

2.09

1.62

N/A none

none

n/a

17.72% 26/07/2005

NONE

2.37

1.33

N/A none

none

n/a

11.82% 29/06/2004

NONE

4.00

3.60

N/A none

none

n/a

PRODUCTION PART APPROVAL PROCESS (PPAP)

PART DRAWING & DIMENSIONAL REPORT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

23/29

21

20

19 18

17

16 11 2

10

15

14

9

8 13

5

7

12 6

4

1

3

PRODUCTION PART APPROVAL - DIMENSIONAL RESULTS Supplier: BOURNS ELECTRONICS Customer P/N : 3714X-BFY-000

Revision

C

Unit 1 Item

Nominal Tol + Tol - Units

Min

Max

Special

Bourns P/N : 583 242 99 B Description : RESISTOR, THICK FILM Measurement Method : Smartscope Unit 2 Unit 3 Unit 4 Unit 5

Actual

OK

Actual

OK

Actual

OK

Actual

OK

3 3 3 3 3 3 3

35.9179

3 3 3 3 3 3 3

35.9182

3 3 3 3 3 3 3

35.9056

3 3 3 3 3 3 3

DIM1

35.9

0.10

-0.10

35.8958

35.9182

35.9179

DIM2

16

0.10

-0.10

15.9993

16.0097

16.0001

DIM3

0.635

0.05

-0.05

0.6100

0.6200

0.6200

DIM4

15.85

0.05

-0.05

15.8006

15.8618

15.8073

DIM5

4.45

0.10

-0.10

4.3796

4.4544

4.4544

DIM6

3

0.15

-0.15

2.9972

3.0282

2.9972

DIM7

5

0.15

-0.15

4.9931

5.0386

4.9931

DIM8

0.3

0.10

-0.10

0.8164

0.8216

0.8191

DIM9

14.5

0.20

-0.20

14.5069

14.5475

14.5475

DIM10

16.5

0.05

-0.05

16.5414

16.5472

16.5472

DIM11

18.5

0.25

-0.25

18.4795

18.5144

18.5144

DIM12

2.9

0.10

-0.10

2.8466

2.9076

2.8618

DIM13

5.85

0.15

-0.15

5.8601

5.9043

5.8601

DIM14

53.19

0.50

-0.50

53.5253

53.6889

53.6889

DIM15

56.19

0.50

-0.50

56.2135

56.3012

56.3012

DIM16

73.87

0.50

-0.50

73.8953

73.9500

73.9500

DIM17

89.02

0.50

-0.50

89.0379

89.0938

89.0749

DIM18

104.45

0.50

-0.50

104.4698

104.5508

104.5065

DIM19

109.9

0.50

-0.50

109.9144

109.9994

109.9399

DIM20

122.42

0.50

-0.50

122.4417

122.5419

122.4500

DIM21

126

0.50

-0.50

126.2407

126.4399

126.2786

15.9998 0.6200 15.8096 4.3836 3.0048 5.0130 0.8174

3 3 3 3 3 3 3 3 3 3 3 3 3

14.5069 16.5436 18.4795 2.8581 5.8882 53.5253 56.2245 73.9241 89.0938 104.5508 109.9994 122.5419 126.4399

15.9995 0.6200 15.8618 4.3796 3.0282 5.0386 0.8164

3 3 3 3 3 3 3 3 3 3 3 3 3

14.5220 16.5414 18.4934 2.9076 5.9043 53.6193 56.2135 73.8977 89.0621 104.4941 109.9605 122.4979 126.2407

16.0097 0.6100 15.8006 4.4085 3.0044 5.0005 0.8216

3 3 3 3 3 3 3 3 3 3 3 3 3

14.5117 16.5447 18.4920 2.8466 5.8789 53.6134 56.2358 73.9106 89.0604 104.5221 109.9684 122.5010 126.3801

Actual OK 35.8958 15.9993 0.6100 15.8252 4.4057 3.0055 5.0311

3 3 3 3 3 3 3

0.8194

3 3 3 3 3 3 3 3 3 3 3 3 3

14.5309 16.5444 18.5043 2.8581 5.8887 53.5282 56.2272 73.8953 89.0379 104.4698 109.9144 122.4417 126.3533

3 3 3 3 3 3 3 3 3 3 3 3 3

PRODUCTION PART APPROVAL PROCESS (PPAP)

RESISTANCE MEASUREMENT REPORT

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

24/29

Supplier: BOURNS ELECTRONICS Customer P/N : 3714X-BFY-000

Revision

C

Bourns P/N : Description : Measurement Method : R6 R7 R8

RST.# NOM. TR. Ω

R1

R2

R3

R4

R5

2.00

5.00

17.00

32.50

50.00

70.00

120.00

Tolerance +

0.50

0.50

0.50

0.50

0.50

0.70

1.20

1.25

Tolerance -

-0.50

-0.50

-0.50

-0.50

-0.50

-0.70

-1.20

-1.25

1.9571 1.9586 1.9641 1.9654 1.9668 2.0146 1.9978 1.9961 1.996 2.0174 1.9954 2.001 1.9976 1.9979 1.9835 2.0091 1.9934 1.9944 2.0045 1.9859 1.9793 1.9756 1.966 1.961 1.9652 2.0004 1.9807 1.9805 1.9871 2.0017 1.9915 1.9876 1.9712 1.9749 1.981 1.9918 1.9996 1.9733 1.9723 1.9928 2.2248 2.2009 2.1958 2.2068 2.2201 1.9753 1.9717 1.982 1.9775 1.9794

5.0455 4.9708 5.1183 5.1171 4.9605 5.0553 5.1506 5.0464 5.0308 5.0305 5.1542 5.0454 5.0098 5.0602 5.0899 5.0402 5.1129 5.1028 5.031 5.0445 4.9934 5.0825 4.9686 5.0874 4.9777 5.1785 5.0044 5.1058 5.0871 5.0724 4.9903 5.1488 4.9906 4.9797 5.0072 5.1638 5.0066 5.0317 5.1322 5.1354 5.2413 5.2474 5.2742 5.2529 5.2914 5.0116 5.0925 5.0394 5.021 5.1157

16.958 16.975 16.969 16.964 16.968 16.989 16.991 17.011 17 17.009 16.997 16.994 17.002 17.001 16.987 17.003 17.009 17.001 17.002 16.988 16.984 16.98 16.984 16.977 16.974 16.995 16.997 17.002 16.983 16.992 16.993 16.998 16.99 16.983 16.986 16.983 16.992 17.004 16.985 16.999 17.203 17.193 17.193 17.202 17.223 16.986 16.971 16.987 16.968 16.991

32.466 32.454 32.454 32.464 32.469 32.493 32.497 32.502 32.484 32.52 32.504 32.503 32.493 32.514 32.511 32.502 32.5 32.499 32.498 32.496 32.487 32.48 32.489 32.469 32.491 32.491 32.485 32.506 32.501 32.498 32.497 32.501 32.484 32.477 32.484 32.492 32.501 32.501 32.47 32.481 32.689 32.693 32.705 32.709 32.718 32.488 32.5 32.481 32.484 32.476

49.961 49.964 49.98 49.981 49.979 50.032 50.008 50.018 50.074 50.027 50.012 50.015 50.013 50.021 50.003 49.99 50.012 50.012 49.982 49.994 50.007 49.991 49.977 49.978 49.981 50.004 50.003 49.995 50.005 50.006 50.005 50.008 49.99 49.985 49.985 50.019 50.005 50.021 50.022 49.998 50.208 50.204 50.213 50.23 50.215 49.997 49.986 49.988 49.98 50.018

69.935 69.911 69.916 69.98 69.901 69.955 69.97 69.969 69.94 69.999 69.977 69.949 70.031 69.942 69.994 69.955 69.949 69.947 69.975 70 69.893 69.963 69.965 69.947 69.924 69.959 69.965 69.959 69.974 69.923 69.954 69.949 69.943 69.961 69.935 69.94 69.993 70.005 69.943 69.941 70.169 70.156 70.122 70.153 70.257 69.887 69.962 70.116 69.939 69.957

120.03 120.03 120.04 120.1 120 120.07 120.07 120.13 120.07 120.09 120.09 120.08 120.06 120.08 120.08 120.14 120.1 120.09 120.03 120.09 120.04 120.1 120.04 120.07 120.08 120.01 120.04 120.1 120.09 120.11 120.07 120.15 120.07 120.1 120.13 120.1 120.06 120.13 120.09 120.05 120.3 120.24 120.27 120.34 120.29 120.07 120.09 120.04 120.05 120.11

125 125.03 125.07 125.07 125.01 125.05 125.06 125.07 125.07 125.09 125.04 125.06 125.01 125.09 125.11 125.12 125.1 125.09 125.04 125.1 125.01 125.11 125.03 125.09 125.04 125.02 125.03 125.07 125.08 125.07 125.05 125.08 125.07 125.1 125.07 125.07 125.07 125.09 125.06 125.03 125.29 125.22 125.29 125.31 125.28 125.02 125.06 125.02 125.03 125.06

MEAN Std. Dev.

2.01 0.07

5.08 0.08

17.01 0.07

32.51 0.07

50.02 0.07

69.98 0.08

120.10 0.07

125.08 0.07

Max. Min.

2.22 1.96

5.29 4.96

17.22 16.96

32.72 32.45

50.23 49.96

70.26 69.89

120.34 120.00

125.31 125.00

Cm Cmk

2.39 2.36

2.00 1.68

2.52 2.47

2.52 2.46

2.47 2.36

3.09 3.00

5.53 5.08

5.72 5.35

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

NAME:

Caroline Hickey

DATE:

10/11/2005

125.00

583 242 99 B RESISTOR, THICK FILM Keithley Multimeter

PRODUCTION PART APPROVAL PROCESS (PPAP)

MATERIAL CERTIFICATION & IMDS APPROVAL

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

25/29

3714X-BFY-000

583 242 99

PRICOL 50053028

10/11/2005

05/0664

05/09/2005

1367

27/10/2005

DUPONT RESIST QS 871

PFP296

20/9/2005

DUPONT RESIST QS 872

PFP243

CERAMTEC

TANAKA 4865

11/10/2005

CAROLINE HICKEY

23/11/2005 PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

26/29

PRODUCTION PART APPROVAL PROCESS (PPAP)

APPEARANCE APPROVAL REPORT & PACKAGING DESCRIPTION

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

28/29

Fuelcard Appearance Approval Report PART NO.

DRAWING NO.

3714X-BFY-000

SUPPLIER NAME

583 242 99 SUPPLIER CODE

MANUFACTURING LOCATION

BOURNS ELECTRONICS

IRL

DEFECT DESCRIPTION

PASS

VOIDS

✔

FAIL

DSZ QA

COMMENT

✔ ✔ ✔

PROTRUSIONS SOLDER COVERAGE BLISTERS

JAGGED EDGES

✔ ✔ ✔

OPEN CIRCUITS

✔

SHORTS

✔

CONTAMINATION

✔

SMEARS/SMUDGES

✔

SCRATCHES MARKINGS

OTHER INSPECTED BY CAROLINE HICKEY

TELEPHONE NO.

CUSTOMER USE ONLY CUSTOMER REPRESENTATIVE SIGNATURE

✔

DATE

00353 21 4515 381 MARK MARTIN

PPAP DOCUMENT NO.:0009-P ECO No.:05-0168

BOURNS ELECTRONICS IRELAND

29/29