AIAG PPAP / EMPB VDA Checkliste Return due date: 14/ Nov/ 08 Supplier: Kobe Prototype: Prototype Project No: Test Projekt Series: Serie Description ZB Komfortöffner li BMW E 61 Kobe ISPO No: 49 Drawing No: 89720023901 Index: IMDS No.: 2 ID No: 897200230901 Q/S status: E (see part history) (12 numbers) Cont. Documents required Checked in N°: 01 Check list for initial sampling 02 Sample parts (5 parts per cavitity) 03 Initial sample report (ISIR) 04 Dimensional test (all results in line with BOS specification must be provided) 05 Function check (in line with BOS drawing/specification) 06 Material test (in line with customer drawing/specification) 07 Haptics test (in line with customer drawing/specification) 08 Accustic test (in line with BOS drawing/specification) 09 Odour test (in line with customer drawing/specification) ( Measurement analysis report of the spectral analysis of 10 Visual Check reference, respectively basic samples, as well as intial sampels) 11 Surface test (in line with customer drawing/specification) 12 EMC test (electro magnetic competibility) 13 Reliablity test (in line with BOS drawing/specification) 14 Design FMEA ( tools / jigs ; proof / status) 15 Design approval (of the supplier in case of a develeopment responsibility) 16 Process FMEA (proof / status) 17 Process flow chart (inculding production and control stations) 18 Control Plan 19 Proof of process capability (according to agreement with BOS) 20 Measurement and test equipment list with calibration approval 21 Control capability proof (MSA, results) 22 EU safety data sheet (if required) (Indication of the BOS approved IMDS-ID/version on the ISIR / 23 IMDS PSW) 24 Transport/packaging (logistics data sheet BOS) 25 Certificates (inspection approval certificate, certification) 26 Process accaptance (internal and external by customer) 27 QFP cover sheet BOS (other attachments) 28 Contact list / team (attachment 2) 29 Achieved cycle time (attachment 3) 30 Action plan for each deviation LOP* (attachment 4) 31 Part history (see attachment 5) 32 List of work/test instructions with approval status 33 Approved drawings (stamped) / data set/specification 34 Tooling list (Part qty or number of cavities and statement on tooling quality) 35 Approval list supplier parts / supplier material 36 Training records of series personnel (all shifts) Information on coating of presented samples (coating system 37 approval according to customer standards) (e.g. environment, security, 38 Proof of legal respoonsabilities recycling, VOC standards) 39 Other Defined: D. Agurkis Approved: C. Herrington Version 2.0; 2008-10-27 COP3_F64 31e62505-35ef-49d7-9ad5-df9ddd76dcda.xls 1 / 10 Contact list for customer: BOS Project: Description: Department Name Tel Mobile phone Fax e-mail Project Management Sales Supplier Project Buyer Project Quality Engineer Quality Manager Managing Directors Department Name Tel Mobile phone Fax e-mail Project Management Lead Designer BOS Headquarters Project Buyer Project Quality Engineer Plant SQE Regional SDE Postal Address to which the PPAP / VDA sample parts must be shipped to for the attention of the Plant SQE as mentioned above. Defined: D. Agurkis Approved: C. Herrington Version 2.0; 2008-10-27 COP3_F64 31e62505-35ef-49d7-9ad5-df9ddd76dcda.xls 3 / 10 Calculation of required and proven cycle times Subject Number Description: Supplier: Q-Status: Planned quantities Requested daily capacity parts Shifts per day shifts Hours per shift hours Working days per week days Average working hours per day based on 5-day week: parts (Shifts per day x hours per shift x working days per week/5) Required cycle time parts per hour (Required daily capacity/ shifts per day x hours per shift x working days per week/5) Results from production tests Manufactured parts: hours ok parts: parts Production time: hours Retooling times per day: hours Machine availability (maintenance, stoppages, % etc.): Effective working time per day: % (Average working hours per day – retooling times per day)/(average working hours per day) Proven cycle time: parts per hour (Qty of good parts. x machine availability x eff. Working time)/production time) Results: Required cycle time was achieved: Yes No Date Signature supplier Defined: D. Agurkis Approved: C. Herrington Version 2.0; 2008-10-27 COP3_F64 31e62505-35ef-49d7-9ad5-df9ddd76dcda.xls 4 / 10 Customer: BOS GmbH & Co. KG Date of creation: Changed by: LOP Contact BOS: Supplier: Distributor: Change date: Rev.: 00 Due Date Date of entry: Responsible closed for the implementation overdue Position (if not coordinator) Loc. Dep. Name: Plan Closed Comments Topic Problem Action Coordinator: Defined: D. Agurkis Approved: C. Herrington Version 2.0; 2008-10-27 COP3_F64 31e62505-35ef-49d7-9ad5-df9ddd76dcda.xls 5/9 Insert Customer Logo here Part History Description: Supplier: Supplier N°.: Part N°.: Internal Part N°.: Production Site: Assy N°.: Internal Assy N°.: Sampling Site: Changed by: Cahnge date: Agreed: Delivery Rev.: 00 1. Date 2. Name Prototype Samples Date Quality 0 Series 3. Department Delivery N° Series Process Status Drawing Customer 4. Company and Pos. Description of Change (E, Q, S) Date Index Approval N°. Date Comments: Defined: D. Agurkis Approved: C. Herrington Version 2.0; 2008-10-27 COP3_F64 31e62505-35ef-49d7-9ad5-df9ddd76dcda.xls 6/9 0. Introduction The EMPB / PPAP Checklists shall provide an easy to handle tool to transfer the complete PPAP / EMPB Over view of what the check sheet is designed to 0.1 documentation. achieve. The wanted documents refer to the VDA / AIAG manuals and are conform to them. 0.2 Technical Contact of the BOS Group Mr. Carlton Herrington, Director SQM If you have any questions concerning the checklists, improvements, corrections or the translation into another 0.3 Contact for Changes of the Checklists language, contact Mr. Fabian Krüger, QMI 0.4 Version Released Version 2.0 0.5 Date 10/27/2008 1.0 General Information Dependent on which OEM we are delivering to and with approval level is wanted, the supplier will have to respect different customer requirements. By choosing the "Type of Checklist" in the Table "Checklist" the necessary reports to hand in will be marked with "yes". You can choose between the level 1 till 3 of the EMPB VDA or the PPAP AIAG, as well as BOS Prototypes, BOS Product Changes and BOS Requalification required documents. 1.1 Checklists The Checklist "Special Requirements" allows to generate and individual checklist, according to needs beside the standards. The List of the required documents ("Checklists") consists of the name of the report, a short description, the indication if it is wanted for the choosen approval level and a check in button. 1.2 Documentation It is only possible to check in reports, which have the pdf format. Be consicous that each report added will increase the final file size. Standard firewalls will have a size limit for email attachments they are accepting. Keep the total size of your checklist lower than 10MB, then it should be possible to pass most IT protections. 1.3 Reports BOS personal must specify all relevant team member details. Supplier must complete their own. Checksheet with attached documents must be e-mailed to: - Project Buyer 1.4 BOS Contacts for the PPAP Process - Plant SQE - Project Quality Engineer - Region SDE (where contact details are available) 2.0 Handling and Functions Reports and documents can be checked in, by clicking on the grey "Check in"-button on the right side. If the document is required for the PPAP / EMPB approval level, it will be marked with a "yes". Already added reports will appears on the following sheet "reports" in green and will be marked with an "ok" tick. 2.1 Check in Reports Added reports can be open by a double click. Only one pdf, file per requirement should be checked in. 2.2 File Size File size should be less than 10MB. 2.3 Compressed file size In case you do have a larger file try to compress it with a standard program, e.g. Win Zip. You can choose between an english and a german version. Click on one of the flags in the upper right corner of the "Checklist" Table. 2.4 Language Use a format, which can be understood worldwide. Remeber date formats are different in the U.S.. 2.5 International Formats Use the following formatiing: DD.MM.YY, e.g. 27. OCT 2008 To reset your form or to use it for an other PPAP / EMPB Process, click on "Reset Form" next to the flags in the 2.6 Reset Form for BOS use only. "Checklist" Table.