KSS Global Standard Product Characteristic Classification

KSS GLOBAL STANDARD

Product Characteristics Classification (CC/SC Guideline)

KSS 050

Document No: 1033079

Authors: Approved by: Approved by: Approved by: Approved by: Gnther Hilbich

Andreas Staub Jim Scarpa Tim Maly Dieter Hahn

(electronic signature on file) (electronic signature on file) (electronic signature on file) (electronic signature on file)

Document History Revision: 1 Release Date 22 Sep 2011 ECP No. 47830
Fully revised standard

Modification

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Table of Content

INTRODUCTION ................................................................................................................................................. 3 1 2 3 4 5 6 7 PURPOSE................................................................................................................................................... 3 SCOPE........................................................................................................................................................ 3 RESPONSIBILITY ...................................................................................................................................... 3 DEFINITION ................................................................................................................................................ 3 DETERMINATION OF SPECIAL CHARACTERISTICS ............................................................................ 4 REFERENCES (RELATED DOCUMENTS)............................................................................................... 9 APPENDICES ............................................................................................................................................. 9

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Introduction
This KSS Standard outlines requirements for how to control potential risks related to product and process through the identification and management of special product and process characteristics (named Critical Characteristics and Significant Characteristics).

Purpose
The purpose of this standard is to facilitate and to harmonize the use of special characteristics within drawings and other documentation throughout the KSS group. It explains the management and handling of special characteristics to fulfill functional and regulatory requirements.

Scope
All KSS sites, organizations, and suppliers must adhere to this standard.

Responsibility
The Engineering Manager or Director of each KSS engineering department is responsible to ensure that the CC/SC standard is followed, monitored and observed during development. The Product Engineer is responsible to define the CC/SC for all engineering documentation associated with development for the assigned programs. The Quality Manager/ Director is responsible to ensure that requirements defined in this standard are implemented. The Procurement Director and Director of Supplier Quality are responsible to communicate this standard and enforce compliance at the supplier level.

Definitions
A characteristic is a dimension or a physical, chemical, electrical, mechanical or visual property. A characteristic must be measurable, either directly or indirectly, either variable or attribute. Attribute characteristics are qualitative data that is measured or checked and results in conformance or non-conformance, pass or fail.

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Variable characteristics are quantitative data which can be measured, and the result is an absolute measurement reading eg. Millimeters, Inches, Newtons, etc. There are two different types of special characteristics: Critical Characteristics (CC) are product characteristics that may affect the safety of product or operator compliance with legal requirements environmental requirements. These characteristics are designated in the D- or PFMEA, having a causal relationship to the effect of potential failure modes rated 9-10 for severity. Significant Characteristics (SC) are product characteristics that may affect form, fit or function of the product the production (assembly) process These characteristics are designated in the D- or PFMEA having a causal relationship to the effect of potential failure modes rated 5-8 for severity, or where agreed by the cross-functional team, having severity rated less than 5. SC characteristics may be influenced by the manufacturing process (KSS and/or suppliers) and may require special control to maintain the required process capability and customer requirements.

5
5.1

Determination of Special Characteristics

Identification Source of special characteristics DFMEA DFMEA PFMEA PFMEA Customer or internal requirements Legal, environmental requirements Criteria Severity rating = 9, 10 Severity Rating = 5 8 Occurrence= 4-10 Severity rating = 9, 10 Severity Rating = 5 8 Occurrence = 4 10 Outcome CC SC CC SC CC or SC CC

Note: A special characteristic (CC or SC) derived from DFMEA may not automatically be carried through to drawing and control plan.

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5.2 CC/SC List Each DFMEA/PFMEA requires a CC/SC list as a controlled document (see appendix) and is to be understood as a subset of the DFMEA. The purpose of the CC/SC list is to monitor and assure that all special characteristics are effectively controlled and documented during development and ongoing production. It is a mandatory document and shall be used for each product. Task Owner of the CC/SC List *) List all CC/SC (column A to M) Input of Data (column N-R) Suppliers Input of data (ppk, cpk, column N,O) Input of data (column N-R) KSS Process Responsible Product Engineer Product Engineer SQE SQA, (SQE) Process Engineer

*): In case of not timely deliverable of data, immediate escalation to Program Manager (PM) is indicated. PM to escalate latest in TG review. 5.3 Control of CC/SC

5.3.1 During Development All special characteristics determined as CC/SC during FMEA process shall be carried forward to the CC/SC list, the drawings, the control plans, and to standard work instructions. All CC/SC shall be verified and validated during Design Validation (DV). The supplier shall evaluate and implement the measurement method approved by KSS and other appropriate controls on characteristics related to their processes. The supplier shall evaluate their processes and further identify, document, and control additional contributing characteristics. All CC/SC shall be verified prior to any DV or customer builds. 5.3.2 During PPAP and Product Validation (PV) All CC/SC on the drawings, control plans and other documents shall be referenced in the PPAP documentation and proven capable. Process capability must be proven for each special characteristic
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If capability cannot be demonstrated, 100% check must be performed with proven detection of non-compliance If this is not possible other methods must be applied (e.g Poka-yoke) Compliance of attribute characteristics can be proven by using a certificate.
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The initial process capability study is to evaluate: The conformity of characteristics to the specified requirement and the effect of tool/process variation on these characteristics. If material is identified as a CC a material certificate must be included in PPAP submission and must be available for each batch/lot during mass production. Capability studies shall be performed according to the AIAG manual Statistical Process Control (SPC), and measurement equipment shall be proven acceptable according to the AIAG manual Measurement Systems Analysis (MSA)/ ISO/TS 16949, latest editions. Suppliers shall demonstrate their ability to perform capable measurement of special characteristics according to methods agreed by KSS. Evidence shall be provided during supplier APQP process. 5.3.3 During Serial Production All CC/SC on the drawings, D- and PFMEA, and/or specifications shall be verified during serial production and reflected in approved control plans. 5.4 CC/SC List Management

5.4.1 All CC/SC lists shall be written in English. Dual language (local language and English) can be applied as applicable. 5.4.2 Distribution of the complete CC/SC list data outside of KSS (customer or supplier) is prohibited, as well as PFMEA, but can be presented upon request. The supplier shall be provided with the CC/SC list for his component.

5.5

Documentation of Special Characteristics CC/SCs must be marked on the drawing according to the global KSS drafting standard. General numbering of characteristics (dimensions) or

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Table on the drawing specifying the identification number of the characteristics

Some more examples

5.6

Documentation/Record retention All documents referring to special characteristics shall be written in English or in dual language (local language and english) Record Retention is mandatory for each document and/or report referring to special characteristics.

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5.7 Summary and FAQ

CC
1 When to apply a CC/ SC Affects product and operator safety and/or compliance with regulatory requirements.

SC
Affects product form, fit or function (other than safety and regulatory) or has other valid reasons to classify significant Yes, temporarily

3 3.1

Is a deviation approval possible in case out of spec.? For new design and new tool after 31 Oct 2011 Evidence for PPAP approval

No

3.2

Evidence in serial production

Initial capability Ppk>2.0 or Poka-Yoke or 100% detection If the CC applies to material, a material certificate is required Continuous capability Cpk >1.67, if verification indicated by SPC (Statistical Process Control) or Poka-Yoke or 100% detection If the CC applies to material, a material certificate is required on request.

Init. capability Ppk >1.67 or Poka-Yoke or 100% detection (material spec. applies to CC classification) Continuous capability Cpk >1.33, if verification indicated by SPC (Statistical Process Control) or Poka-Yoke or 100% detection (material spec applies to CC classification)

4 4.1

Existing design or tools before 31 Oct. 2011 Evidence for PPAP approval

Initial capability Ppk>1,67 Init. capability Ppk >1.33 or or Poka-Yoke Poka-Yoke or or 100% detection 100% detection If the CC applies to (material spec. applies to material, a material CC classification) certificate is required

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4.2 Evidence in serial production Continuous capability Cpk >1.33, if verification indicated by SPC (Statistical Process Control) or Poka-Yoke or 100% detection If the CC applies to material, a material certificate is required on request. Continuous capability Cpk >1.33, if verification indicated by SPC (Statistical Process Control) or Poka-Yoke or 100% detection (material spec applies to CC classification)

References (Related Documents)

- KSS Quality First Manual - KSS Global Drafting Standard

Appendices
Attachment: CC/SC list template

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