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IMDS Reporting Requirement Specification

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					IMDS Reporting Requirement Specification
                      Keykert 4904 2004 Revision 01
                         Released October 28, 2005




Released 10/28/2005                        Printed Copies are Uncontrolled
   IMDS Reporting Requirement Specification KEYKERT 4904 2004 rev-01


   Table of Contents
   General Information / Objective………………….……………Page 3

   IMDS Reporting Requirements……………………………..…Page 4

   IMDS / PPAP / APQP…………………………………………..Page 5

   Delinquent Reporting………………………………………......Page 6

   Submission Requirements…………………………………….Page 6-8

   Rejection Codes………………………………………………...Page 9-10

   IMDS Structural Illustrations……………………………….......Page 11-12

   IMDS Training information……………………………………..Page 13

   Keykert/Kiekert IMDS contacts….…………………………….Page 14

   Appendix A………………………………………………………Page 15-18
     (DPS form)

   Appendix B………………………………………………………Page 19-20
     (IMDS Definitions)

   Appendix C………………………………………………………Page 21-22
     (Examples of common reporting errors)

   Appendix D………………………………………………………Page 23-24
     (Searching for ILI-metals)

   Revision history …………………………………………….......Page 25




                     All revisions and additions are highlighted in grey




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  The objective of this specification is to provide Keykert USA and Kiekert de México
  suppliers with:
         Guidelines and requirements for reporting to Keykert USA and Kiekert de
         México
         Reporting requirements for the International Material Data System (IMDS)
         Additional information and supporting instructions for using IMDS and reporting
         via IMDS (e.g.: ILI-metals, IMDS Recommendations, etc.)
         IMDS definitions/terminology

  Four components for creating and releasing component/material data via IMDS:
    1) IMDS registration – suppliers must be a registered IMDS user
    2) Define materials via IMDS
    3) Construct product tree structure (MDS)
    4) Submit/Release Material Data Sheets (MDS) to Keykert IMDS ID #1875

   Access IMDS @ http://www.mdsystem.com




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  Keykert USA, Inc. and Kiekert de México IMDS Reporting Requirements

  Materials
  One hundred percent (100%) of all materials must be detailed in IMDS using either
  specific or generic (where permissible) material designations.

  Substances
  All substances that are contained in a material (specific and/or generic) shall be fully
  disclosed. Keykert/Kiekert will not accept submissions with information classified as
  confidential.

  The use of generic substances or “jokers” is acceptable; however, “joker/wildcard”
  declaration shall not exceed 10% of the mass of the homogeneous material.

  Generic substances are not permissible in lieu of disclosing prohibited or declarable
  substances.

  The four restricted heavy metals (hexavalent chromium (Cr6+), lead, cadmium, and
  mercury) must be fully disclosed regardless of their percentage or weight.

  All prohibited or declarable substance defined by the GADSL list (Global Automotive
  List of Declarable Substances), and/or Keykert/Kiekert internal requirements shall be
  disclosed.

  It is the responsibility of the supplier of the parts and/or raw materials to ensure
  compliance with the requirements of:
         The latest ELV Directive (2000/53/EC) including supporting amendments (e.g.:
         Annex II)
         Current GADSL list
         For all applicable customer specific requirements (e.g.: Keykert→4904 2004,
         FoMoCo→WSS-M99P9999-A1, etc.)
         Current IMDS system reporting requirements (e.g.: version 3.1 - polymeric part
         marking requirement)

  Suppliers are responsible for ensuring that all submissions are in accordance to this
  IMDS reporting specification (4904 2004), as well as, all applicable IMDS
  Recommendations.

  All IMDS reporting to Keykert USA is to be provided in English. Submissions received
  in other languages are subject to rejection.




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  IMDS/Production Part Approval Process (PPAP) and Advance Product Quality
  Planning (APQP) requirements

  Material certifications must accompany all PPAP submissions per AIAG’s PPAP
  guidelines.

  An IMDS submission is required for each component prior to or at the time of PPAP
  submission. PPAP submission will not be accepted until all applicable parts are
  submitted, reviewed, and approved via IMDS, and is in accordance to Keykert/Kiekert
  PPAP guidelines.

  Based on IMDS volume, IMDS submissions and all supporting documentation should
  be submitted at least four weeks prior to the PPAP due date. All IMDS submissions
  are reviewed in the order they are received.

  Substances detailed on material certifications must match the substance breakdowns
  detailed in IMDS unless ILI-metals are used.

  If a supplier’s IMDS submission is rejected for any reason, full PPAP approval will not
  be granted until the submission has been corrected, re-submitted (full PPAP approval
  is required before the release of final tooling payments), and approved.

  IMDS reporting has been integrated into the APQP process. Impurities caused by
  prohibited substances shall be recorded qualitatively and risk estimates should be
  discussed in a dialogue.

  Production & Production intent Suppliers
  All prohibited substances must be declared and approved prior to use. Declaration
  shall be made via Keykert/Kiekert’s Declarable/Prohibited Substance Reporting and
  Approval Form (FCD-0334).

  When declarable or prohibited substances are present, the form must be completed
  and submitted early in the development phase (see appendix A).

  This will allow adequate time for re-design and/or re-validation with an alternate
  material, should either Keykert/Kiekert and/or our customer not approve the current
  application.




  **Substances not approved by Keykert must be eliminated from the product. **




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  Delinquent Reporting

  Suppliers that do not report their parts via IMDS and/or are delinquent in reporting
  will:
      Be charged a daily administrative cost per missing part until all submissions are
      received and approved (amount to be negotiated according to cost incurred by
      Keykert/Kiekert)
      Not receive PPAP approval
      Not have pending tooling orders honored for payment (partial payments may be
      withheld)
      Have points deducted from supplier rating
      Placed on probation
      Placed “new business hold” and may be subject to de-sourcing of current business
      Suppliers will subsequently be responsible for charge-backs incurred by
      Keykert/Kiekert from our respective customers as a result of missing, inaccurate,
      or false IMDS reporting and/or usage of prohibited/restricted substances not
      approved by Keykert USA, Inc.

  Keykert USA / Kiekert de México IMDS Submission Requirements

  When an IMDS submission is required
  An IMDS submission is required:
     ♦ With all PPAP submission and/or revision level bumps
     ♦ A change in mass of a part exceeding the tolerance listed on the production
        part drawing or the Part Submission Warrant (PSW)
     ♦ When design, specification or material changes occur
     ♦ When using alternative materials, as detailed on the Keykert drawing
     ♦ When suppliers of products or services are changed
     ♦ Upon request, if non-compliance to legal conditions are suspected
     ♦ When revisions to the GADSL change the status, reporting requirement, or
        threshold of a substance
     ♦ IMDS system enhancements or changes may affect how data is reported, and
        may result in a re-submission in some cases (if applicable, suppliers will be
        notified)

  All components within a purchased assembly must be created as “components” and
  NOT as a “semi-components” via IMDS.

  *Note: A semi-component as defined in IMDS is not applicable for Keykert/Kiekert
  components; therefore, semi-components shall not be used in any submission to
  Keykert/Kiekert.




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  If the assembly contains components that have Keykert/Kiekert part numbers, the
  Keykert/Kiekert part numbers must be detailed (including the revision level) for each
  applicable component. If an assembly contains components that do not have
  Keykert/Kiekert part numbers then the component(s) may be detailed with PIA
  (Purchased In Assembly) as the part number.

  A PIA part number is only acceptable if the part/component within a purchased
  assembly Does Not have a Keykert/Kiekert part number.

  Supplier Reporting Requirements
  Suppliers shall submit all parts to Keykert USA via IMDS ID #1875 and must include
  the following:

         Keykert/Kiekert part number and revision level (e.g. 4900210000)
         Keykert/Kiekert part description (e.g. IVH Catch Complete) as detailed on the
         drawing
         Detail 0 for Recyclate information (required for all plastic parts)
         Detail application codes, when applicable
         Certify polymeric parts are appropriately marked (in accordance to ISO
         11469/1043/1629)
         Full disclosure of all applicable materials, substances, coatings, and plating (in
         their cured state)
         Material names shall define the material. The use specification numbers (e.g.:
         WSS-M21P27-A1 instead of Magni Plating) or generic descriptions are not
         permissible

  Materials and Substances
  It is imperative to preserve the integrity, accuracy, and reliability of each submission;
  therefore, suppliers are required to either create their own materials, or only utilize
  materials that have been created by their material supplier(s).

  *Note1: Metals are an exception. Please see “Reporting of Metals (Steel)” for
  material reporting requirements.

  Suppliers are responsible for the accuracy of the data sent to Keykert regardless of its
  originating source(s).

  Substances cannot be directly attached to a component or semi-component, they
  must be attached to a material.

  *Note 2: Substances shall be reported in their cured state

  Plastics and Rubbers
  Refer to IMDS recommendation 003 for rubber and recommendation 010 for plastics.
  All plastic and rubber materials must be created in accordance to these
  recommendations (see IMDS public pages).


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  For polymeric materials, the designated marking codes in the “Symbol” field.

  Metals (Steel)
  Due to many range variations in reporting metal (steel) materials, which has resulted
  in rejections by the OEMs, the IMDS Committee has pre-loaded over 12000 metal
  materials into IMDS. Keykert/Kiekert has reviewed and adopted the ILI Metals listing.

  Suppliers are required to select metals (steel) from the ILI Metals list in lieu of creating
  their own metal materials in IMDS. Non-compliant submissions will not be accepted
  (see exceptions below).

  **Exception: Suppliers may create their own metal (i.e. steel) material if:
     The material is not already created in IMDS (pre-approval via a DPS form is
     required)
     When there is a significant difference between the suppliers’ metal and the metal
     detailed in IMDS (pre-approval via a DPS form is required)

 *Note: Advance notice does not constitute acceptance, but failure to submit advance
 notice will result in an automatic IMDS rejection.

 Coatings and Surface Treated Metals
 Submissions for components that have a coated or treated metal substrate must have
 at least two materials in the IMDS tree – one for base metal material and one for the
 applicable coating.

 Coating shall be reported in their cured state, and not as with the chemistry of the
 process chemicals or products.




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  Rejection codes

  Many reporting errors are similar in nature. To reduce the amount of time and detail
  required to reject an IMDS submission, effective November 1, 2005 Keykert/Kiekert
  will begin utilizing a code system for rejecting IMDS submissions.

  When applicable, the code table listed below will be used to reject incorrect
  submissions; however, when a more descriptive reason for a rejection is required, the
  additional information will be detailed on the IMDS rejection screen.


      Rejection                                                            Code
      Non-ILI metal used without prior Keykert USA approval                 010
      Part number incorrect / incomplete                                    020
      Part description incorrect / incomplete                               022
      Misc. substance exceed 10%                                            030
      Submission inconsistent with drawing and/or documentation             040
      Improper tree structure (including use of semi-components)            050
      Prohibited/Declarable substance exceeds threshold limitations         060
      Material substances not fully disclosed                               070
      MDS submitted to wrong ID                                             080
      Min/Max variation % exceeds allowable range (max +/- 5%)              090
      Recyclate information missing for plastic parts                       100
      Missing certification for marking of polymeric parts                  110
      Measured weight tolerance shall not exceed +/- 5%                     120
      Drawing and reporting weight difference is exceed +/- 10% **          130




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  Reasons / codes for IMDS rejections:

      Usage of non ILI-metals w/o previous Keykert approval (code 010)
      Incorrect part number format used (code 020):
          o Part number shall be detailed as 10-digits without spaces, dashes or
              symbols (i.e. 4700201003)
      Detailing incorrect part name/description (code 022)
          o All submission must have a Keykert/Kiekert part name/description as
              detailed on the drawing
      Exceeding the allowable misc. declaration of 10% per material (code 030)
      including, but not limited to:
          o Pigments portions or flame retardants
          o Plasticizers, or further additives
      Materials and/or documentation discrepancies (code 040)
          o Material certs do not match IMDS submission and/or material detailed on
              drawing
      Incorrect tree structure (code 050)
          o Materials listed without substances
          o Materials listed as components
          o Parts created as semi-components
      Prohibited or Declarable substances exceeds threshold limits (code 060)
      Material substance are not fully disclosed (code 070)
          o Iron missing in steel
          o Plating not disclosed
          o Labels/Stickers (that remain affixed to the component)
      Part submitted to wrong IMDS ID (code 080)
      Basic substance min/max variation exceeds allowable range (code 090)
          o Substance content             Allowable range
                        • Up to 10%                    ± 1%
                        • 10-20 %                      ± 2%
                        • 20-50%                       ± 3%
                        • 50-100%                      ± 5%
      *Note: Ranges above are for metals only - not plastics. See Recommendation
      010 for the allowable ranges of plastics.
      Recyclate information missing (code 100)
      Certification missing for marking of Polymeric Part (code 110)
      Measured weight tolerance exceeds +/- 5% (code 120)
      When the difference between calculated mass on drawing and measured weight
      in IMDS exceeds +/- 10% (code 130)**

   **Exception: When weight is defined as a CC the +/- 10% rule does not apply. In
   cases, when a tolerance is permissible it shall be specified on the drawing.

   When a submission is rejected, a new (corrected) submission is required within
   three business days. An action plan detailing corrective action is required if a new
   (corrected) submission cannot be completed within three business days.


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   IMDS Tree Symbols and Structure Illustrations
   Component                       Semi-Component       N/A for Keykert/Kiekert
                                                        submissions
   Material                        Substance


                Illustrations of Correct IMDS Tree Structures




                   ILL.1




                                                                           ILL.2




                 ILL. 3


                                                                  ILL. 4


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               Illustrations of Incorrect IMDS Tree Structures




                                           ILL. 6                    ILL. 7




                  ILL. 5




                             ILL. 8




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   Training information
                             www.mdsmap.com




                             www.imds-elearning.com




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                              Keykert USA’s Contact List

Tracey Herrod                              Ernie Mullins
Standards and Materials Coordinator        Quality Manager
46941 Liberty Drive                        1101 Highview Drive
Wixom, MI 48393                            Webberville, MI 48892
Phone: 248-960-4100                        Phone: 517-521-1700
Fax: 248-960-5393                          Fax:    517-521-5296
Email: tracey_herrod@keykertusa.com        Email: ernie_mullins@keykertusa.com

Dennis Cruz
Director of Purchasing
46941 Liberty Drive
Wixom, MI 48393
Phone: 248-960-4100
Fax: 248-960-5368
Email: dennis_cruz@keykertusa.com



                             Kiekert de México Contact List

Tracey Herrod                              Miguel Martell
Standards and Materials Coordinator        Quality Manager
46941 Liberty Drive                        KM 14.5 Autopista Puebla-Orizaba
Wixom, MI 48393                            Chachapa, Pue. México CP 72990
Phone: 248-960-4100                        Phone: 52-222-8918421
Fax: 248-960-5393                          Fax:    52-222-8918404
Email: tracey_herrod@keykertusa.com        Email: miguel_martell@kiekert.com.mx

Victor Romero
Purchasing Manager
KM 14.5 Autopista Puebla-Orizaba
Chachapa, Pue. México CP 72990
Phone: 52-222-8918428
Fax: 52-222-8918427
Email: victor_romero@kiekert.com.mx


Send ALL restricted/reportable and IMDS questions and correspondence to
restricted.reportable@keykertusa.com




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                                     Appendix A

    Declarable / Prohibited Substance Reporting and Approval Form
  All prohibited substances must be declared and approved by Keykert USA prior to
  use.

  Declaration shall be made via the:
  Declarable/Prohibited Substance Reporting & Approval Form (also known as
  DPS form)

  When declarable or prohibited substances are present, the form must be completed
  and submitted early in the development phase of a program.

  The DPS form is available on-line @ http://supplier.keykertusa.com

  When to submit a DPS
  A DPS form is required:
     When a supplier creates metals (non-ILI metals) in IMDS
     When Keykert is design responsible but the supplier’s processes are inclusive of
     substances that are declarable or prohibited in accordance to the GADSL list
     and/or customer specific requirements (DPS required upon business award)
     When Keykert is not design responsible and the supplier’s materials or processes
     contain substances that are either declarable or prohibited in accordance to the
     GADSL list and/or customer specific requirements (DPS required upon business
     award)

  How to complete and submit a DPS
  A supplier can complete a DPS form in one of two ways:
  By component/per material, or
  By material (blanket approval) for multiple components (in cases where a supplier
  uses the same material for multiple components)

  To submit a DPS form by component – per material
     Complete the DPS form (including applicable part numbers and revision levels)
     Ensure substance weight percentages total 100%
     Detail purpose or usage for all declarable or prohibited substances
     Select the applicable destination location
     All materials detailed on the DPS form shall match materials detailed on material
     certifications (trace amounts can be detailed as misc. up to 10% as long as the
     substances are not prohibited or declarable)

Submit the completed DPS form and applicable material certification(s) to Keykert USA
for review and approval.




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  By material (blanket approval) for multiple components
     Create Material and Development Sample Report in IMDS
     Complete DPS form
     Ensure substance weight percentages total 100%
     Detail purpose or usage for all declarable or prohibited substances
     Select the applicable destination location
     Materials reported on the DPS form must match materials detailed on material
     certifications (trace amounts can be detailed as misc. up to 10% as long as the
     substances are not prohibited or declarable)

  Submit the completed DPS form, a material certification for the requested material, a
  copy of the IMDS Initial Sample Test Report, and the IMDS ID version to Keykert USA
  for review and approval.

  In order to certify a material for multiple components, the supplier must submit both
  the IMDS version and the Initial Sample Test Report for the material. When the
  material is approved all applicable components may be submitted with the approved
  material (with the same IMDS version number).

  When the material changes (i.e. new version created in IMDS) the supplier is required
  to submit an updated DPS form, material certification, sample test report, and the new
  IMDS version number to certify the material.


  Send completed DPS forms and all applicable material certifications to
  restricted.reportable@keykertusa.com


  All forms will be reviewed within the APQP process to ensure “substances of concern”
  are eliminated when required and/or minimized to allowable percentages when
  feasible.

  In order to allow for a timely review, supplier must submit all DPS forms and/or IMDS
  submissions (with all supporting documentation) at least four weeks prior to the PPAP
  due date.




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Use “By Component” tab for by component per material DPS submissions. An electronic copy of this form is available on-line
@ http://supplier.keykertusa.com



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Use “By Material” tab for blanket approval of a material DPS submissions. An electronic copy of this form is available on-line
@ http://supplier.keykertusa.com



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                                       Appendix B

                                       Definitions
  Basic substances – chemical elements or chemical compounds as they exist
  naturally or are produced, this includes stabilizing agents and production-related
  impurities (with the exception of solvents) which can be separated without any effects
  on stability or change in composition.

  *Note 1: Substances cannot be directly attached to a component or semi-component,
  they must be attached to a material.

  *Note 2: Substances shall be reported in their cured state.

  Component – is a complete assembly or a component within an assembly that builds
  up a complete part.

  Declarable/reportable substances – are permissible within set limitation but must
  still be declared.

  Material – composition of a component or semi-component, and consisting of one or
  more basic substances.

  Prohibited substances – are prohibited for all or certain application purposes by law.
  They may not be contained in amounts, which exceed their set limitations.

  Material Data Sheet (MDS) – the complete description of a supplied product (can be
  a component semi-component or material).

  Pre-Consumer Recyclate (a.k.a post-industrial) - is recycled material from a
  manufacturing process that is subsequently used for a different manufacturing
  process, whether from the same company or scrap received from another company.
  Home scrap or regrind is NOT considered pre-consumer recyclate material. Pre-
  Consumer Recyclate is reported as the percent of the material’s weight that is pre-
  consumer recycled material.

  Post-Consumer Recyclate - is recycled material originating from products or
  materials that have served their intended end use, and have been recovered or
  otherwise diverted from the waste stream for the purpose of recycling.

  *Note: Pre and Post Consumer Recyclate is not applicable for any Keykert/Kiekert
  components (as detailed on Keykert drawings per WI-0069).

  Semi-component – an item becoming a component through a further processing
  step, like cutting to size. It is otherwise identical to a component, but does not have a
  fixed weight until it is attached to the assembly level part.


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  *Note: A semi-component as defined in IMDS is not applicable for any
  Keykert/Kiekert part; therefore, it shall not be used in any submission to
  Keykert/Kiekert.

  Recycled Material Content
  Recycled content (post-industrial and post-consumer) is required for all non-metallic
  parts (e.g. polymeric materials – plastics and elastomers). Detail zero in the
  appropriate fields for metallic parts.




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                                         Appendix C

                       Examples of common reporting errors
           Creating and reporting materials with a specification number instead of the
           material name (steel detailed as SAE J403 instead of 1010 Hot Rolled, or
           plating detailed as GMW3359 instead of Zinc Plating)

                                                Example 1

Materials may not be detailed with the
specification number as the material name.

The material name should be descriptive
enough so that the material is easily
identifiable (e.g.: plating or zinc plating).

Specification numbers must be detailed in
the “Norms/Standards” section.




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          Exceeding allowable 10% joker/miscellaneous requirement:

   Example 2




  Note: The content of the two joker materials is 20%, which exceeds the maximum
  allowable 10% misc. allowed per component.

  Example 3




Note: The content of the joker and confidential materials exceeds the maximum
allowable 10% misc. allowed per component.



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                                Appendix D

                  Conducting an ILI-Metals material search




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                                  Revision History

 Revision                    Revisions                    Revision         Release
   Date                                                    Level             Date
10/01/2004   -Initial release of IMDS Reporting             00            10/15/2004
             Requirement Spec 4904 2004
10/03/2005   -Replaced reference to ILRS with GADSL           01          10/28/2005
             -Added rejection code table
             -Updated submission requirements
             -Updated DPS form
             -Revised DPS reporting requirements
             -Updated correct/incorrect IMDS tree
             structures
             -Move IMDS definitions to Appendix B
             -Added appendix D – Searching for ILI-
             metals
             -Added Reference to Recommendations
             003 and 010 for plastics and rubbers
             -Added reporting requirements for
             coatings and platings
             -Added Table of Contents




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