Documente Academic
Documente Profesional
Documente Cultură
Blackrock
Cork
Ireland
583 242 99
Part/Family Description:
FUELCARD
Submission Date:
23/11/2005
CONTENTS
TS16949 CERTIFICATION
APPEARANCE REPORT
Note: Has this part been reported in IMDS (or equivalent)? Yes No
SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requirements: YES NO (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.
uantities until
PPAP functional
DOCUMENT approval or waiver is
NO.:0009-P
ECO No.:05-0168
om customer. BOURNS ELECTRONICS IRELAND 5/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
D
O
C Potential e
Potential S c R Responsibility & S O D R
Design Functions Potential l Cause(s) / Current Design t Recommended Actions
Effect(s) of e c P Target e c e P
& Requirements Failure Mode a Mechanism(s) Controls e Actions Taken
Failure v u N Completion Date v c t N
s of Failure c
r
s t
Gauge PPAP sample
Resistor Too Low 7 M Incorrect Design 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too Low 7 M Low ohms/square 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too high 7 M Incorrect Design 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too high 7 M Low ohms/square 4 1 28
Inaccuracy qualification
PPAP sample
Gauge Material unsuitable
Resistor value Drift 6 M 5 qualification, customer 2 60
Inaccuracy for environment
tests
Design Rules, PPAP,
No gauge
Termination Open circuit 8 C Incorrect Design 5 Gerber View, Artwork 1 40
reading
Inspection
Incorrect material
No gauge PPAP sample
Open circuit 8 C selection, Premature 2 2 32
reading qualification
element wear
Include in the product Template
Positioning of probe
Probe mark on resistor Eratic template for all product John O'Connell updated,
8 C points on wiper travel 4 Not listed. 5 160 8 1 5 40
card. opencircuit that requires probing 16-1-05 design
area.
near the potential wiper procedure
Incorrect Circuit Incorrect PPAP sample
7 C Design Errors 7 1 49 12/01/2005
Layout Output qualification
D
O
C Potential e
Potential S c R Responsibility & S O D R
Design Functions Potential l Cause(s) / Current Design t Recommended Actions
Effect(s) of e c P Target e c e P
& Requirements Failure Mode a Mechanism(s) Controls e Actions Taken
Failure v u N Completion Date v c t N
s of Failure c
r
s t
Incorrect gap Design Rules, PPAP,
Termination Shorts circuit Erratic output 7 c 7 1 49
between tracks Artwork Inspection
Drawing checked by
Incompatible
Design Engineer,
Substrate Dimensions Parts not to size with customers 8 M Design Errors 5 1 40
PPAP Sample
assembly
Qualification
Yield Certs of
Receiving Wrong material Supplier error/ No
impact/Line 7 2 Conformance / 3 42 N/A
Inspection (Inks) testing at Incoming
down Supplier evaluation
Print defect -
Open Circuit/ Install & Commission
Print Top Term Voids, Bridging, 8 M Print settings 3 Visual, X-Ray Visual 8 192 SPOS July 2005
Short Circuit Vision detection system
Blobs etc
TR setup check.
TR values out
Resist Print Resist Voids 8 Mi Incorrect setup 3 Resistance check at 1 24 N/A
of spec
laser trim.
Surface
Wiper Stiction 7 Procedure 4 112
Treatment 1 Surface Treatment Pat Bradley
Missed Process Operator Error 4
Shortened process goes in-line. 31st Sept 2005
5 Routing 4 80
lifetime
Reduced track
5 Torque check 3 45
thickness
Operating
Debris on part 5 Incorrect setup 3 45
pressure too high
Smearing of Current check 3
5 45
ink
PPAP DOCUMENT NO.:0009-P
Broken plates 5 45
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 10/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Wiper Stiction 7 56
Worn Active Active element
4 PEMAC 2
Element Shortened wearing with use
5 40
lifetime
Incorrect Active Multiple materials in Stock only 1
Contamination 5 4 3 60
Element stock material
Active Element
Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Damage
Contamination on Contaminated
5 No active cleaning 4 Air knife 3 60
tooling parts
Ink
Wrong plate
smearing/shorti 5 Operator error 3 Procedure/diagrams 3 45
orientation
ng
Surface
Wiper Stiction 7 Procedure 4 112
Treatment 2 Surface Treatment Pat Bradley
Missed Process Operator Error 4
Shortened process goes in-line. 31st Sept 2005
5 Routing 4 80
lifetime
Reduced track
5 Torque check 3 45
thickness
Operating
Debris on part 5 Incorrect setup 3 45
pressure too high
Smearing of Current check 3
5 45
ink
Broken plates 5 45
Wiper Stiction 7 56
Worn Active Active element
4 PEMAC 2
Element Shortened wearing with use
5 40
lifetime
Incorrect Active Multiple materials in Stock only 1
Contamination 5 4 3 60
Element stock material
Active Element
Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Damage
Contamination on Contaminated
5 No active cleaning 4 Air knife 3 60
tooling parts
Ink
Wrong plate
smearing/shorti 5 Operator error 3 Procedure/diagrams 3 45
PPAP DOCUMENT
orientation NO.:0009-P
ng
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 11/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Customer
Dielectric Print, Poorly Covered reject - can Incorrect print set
3 Mi 3 Visual 8 72 n/A
and Cure resist cause end user up.
failure
Customer
Poorly washed Incorrect Investigate potential for
reject, potential 7 Mi 5 Visual 8 280 Sean S.Week 05 Completed 1 4 7 28
part washing,check Corrosion
corrosion
Customer
Singulate into Op - visual QA - Install breaker in shorts TH, ECD - Week 25
Bad breaks cannot use 7 Mi Manual Breaking 5 8 280 Completed 7 2 5 70
units sample / open tester 2001
parts
At set up 1 L/T failure to
Machine Customer Incorrect set July 16 2003 Sean P.,
Shorts, Opens 7 C 3 Electrical test. 5 105 be taken, and tested to Completed 7 3 1 21
dynamic test Issues up.Machine fault Mike D.
verify failure
Final Process Customer Poor training /
No Inspection 7 C 3 Training/SDWT 2 42 n/A
Inspection issues Operator Error
Inspecting 1 PO at
Shipment
Packing Wrong labels 7 Operator error 2 a time. QA checks. 2 28 N/A
Return
Op checks
Inspecting 1 PO at
Customer dis-
Wrong Qtys 7 Operator Error 2 a time. QA checks. 2 28 N/A
satisfaction
Op checks
Inspecting 1 PO at
Customer dis-
Mixed parts 7 Operator Error 2 a time. QA checks. 2 28 N/A
satisfaction
Op checks
Poor communication
More than 1 P/N Customer dis- at shipping/packing
Shipping 5 4 Shipping checks 3 60 N/A
per box satisfaction of customer
PPAP DOCUMENT NO.:0009-P requirement
ECO No.:05-0168 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)
150 160 Laser-Scribe Camber guage Ceramic Mfg. Camber PS-C4000 Camber 5% of Every Log in L/S log Inform Mfg. Engineer for dispositio
Inspection Process Go / No Go ship- ship- book
guage ment ment
Do not process with order.
150 160 Laser Scribe C02 Laser scriber Laser scribing Scribe depth PS-C4000 Toolmakers 1 plate Every Log in MFG050
+ Scope 100 Green Zone = Normal production.
plates Pre-control White Zone = Continue but call
SPC Chart Technician
(MFG217) Red Zone = Stop and inform
Supervisor.
150 160 Laser Scribe C02 Laser scriber Laser scribing Scribe Position PS-C4000 Toolmakers See At setup Check Vs Re-check X+Y scribe m/c
& Product Scope PS-C And start Product template settings. If problem still exists
Template At set up + 4000 of every call technician.
start of every P.O.
P.O. Record
Record results results
+ On MFG 050 On
MFG 050
Break out Product template Vernier 30 6 Cpk >1.5. Manufacturing Engineer to
Dimension Calipers Pieces, Monthly. Calculate with Review and decide on
SPC Kiss. appropriate corrective action
Record results on if required.
Network server
470 480 Resist Print Screen Printer Screen Printing Alignment Product Template Shadow graph 1 plate At set- Record results on Set-up = Reject if outside
+ up & QA1000. tolerance. Adjust printer and
every Check vs Template verify alignment within limits.
100 In Process = Isolate product
plates 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 Every Furnace-room and retarget ink prior to
Resist +
490 500 Drier & Furnace Resistance PS-C4088 database &/ 1 plate 100 database or on processing further
Dry & fire Drier & furnace
settings /profile Multimeter plates MFG194, if D-Base orders.
is not available.
+ Major (Significant)
_ Minor
TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 1.50 1.44 N/A none none n/a
WIDTH (.016+/-.003 INCH) SYSTEM PLATES
TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 0.93 0.92 N/A none none n/a
LENGTH (.010"+/-.003 INCH) SYSTEM PLATES
RESISTANCE MULTIMETER 0.20% 05/07/2004 NONE 2.90 1.68 n/a none none n/a
kiln pre trim HP34401a
LASER TRIM MULTIMETER 8.60% 29/06/2004 NONE 3.13 2.74 N/A none none n/a
RESISTANCE KEITHLEY 2010
QA DIMENTIONAL VERNIER 15.95% 26/07/2005 NONE 2.09 1.62 N/A none none n/a
LENGTH(38.1mm +0.25 /-0.05) MITUTOYO 500-191
QA DIMENTIONAL VERNIER 17.72% 26/07/2005 NONE 2.37 1.33 N/A none none n/a
WIDTH (16.40mm +.25/-.05) MITUTOYO 500-191
QA DIMENTIONAL VERNIER 11.82% 29/06/2004 NONE 4.00 3.60 N/A none none n/a
THICKNESS (.63mm=/-.07mm) MITUTOYO 500-191
PRODUCTION PART APPROVAL PROCESS (PPAP)
20
19
18
17
16
11
2
10
15
14 9
8
13 7
12
5
6
3
PRODUCTION PART APPROVAL - DIMENSIONAL RESULTS
Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 B
Customer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM
Measurement Method : Smartscope
Unit 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 3 35.9179 3 35.9182 3 35.9056 3 35.8958 3
DIM2 16 0.10 -0.10 15.9993 16.0097 16.0001 3 15.9998 3 15.9995 3 16.0097 3 15.9993 3
DIM3 0.635 0.05 -0.05 0.6100 0.6200 0.6200 3 0.6200 3 0.6200 3 0.6100 3 0.6100 3
DIM4 15.85 0.05 -0.05 15.8006 15.8618 15.8073 3 15.8096 3 15.8618 3 15.8006 3 15.8252 3
DIM5 4.45 0.10 -0.10 4.3796 4.4544 4.4544 3 4.3836 3 4.3796 3 4.4085 3 4.4057 3
DIM6 3 0.15 -0.15 2.9972 3.0282 2.9972 3 3.0048 3 3.0282 3 3.0044 3 3.0055 3
DIM7 5 0.15 -0.15 4.9931 5.0386 4.9931 3 5.0130 3 5.0386 3 5.0005 3 5.0311 3
DIM8 0.3 0.10 -0.10 0.8164 0.8216 0.8191 0.8174 0.8164 0.8216 0.8194
DIM9 14.5 0.20 -0.20 14.5069 14.5475 14.5475 3 14.5069 3 14.5220 3 14.5117 3 14.5309 3
DIM10 16.5 0.05 -0.05 16.5414 16.5472 16.5472 3 16.5436 3 16.5414 3 16.5447 3 16.5444 3
DIM11 18.5 0.25 -0.25 18.4795 18.5144 18.5144 3 18.4795 3 18.4934 3 18.4920 3 18.5043 3
DIM12 2.9 0.10 -0.10 2.8466 2.9076 2.8618 3 2.8581 3 2.9076 3 2.8466 3 2.8581 3
DIM13 5.85 0.15 -0.15 5.8601 5.9043 5.8601 3 5.8882 3 5.9043 3 5.8789 3 5.8887 3
DIM14 53.19 0.50 -0.50 53.5253 53.6889 53.6889 3 53.5253 3 53.6193 3 53.6134 3 53.5282 3
DIM15 56.19 0.50 -0.50 56.2135 56.3012 56.3012 3 56.2245 3 56.2135 3 56.2358 3 56.2272 3
DIM16 73.87 0.50 -0.50 73.8953 73.9500 73.9500 3 73.9241 3 73.8977 3 73.9106 3 73.8953 3
DIM17 89.02 0.50 -0.50 89.0379 89.0938 89.0749 3 89.0938 3 89.0621 3 89.0604 3 89.0379 3
DIM18 104.45 0.50 -0.50 104.4698 104.5508 104.5065 3 104.5508 3 104.4941 3 104.5221 3 104.4698 3
DIM19 109.9 0.50 -0.50 109.9144 109.9994 109.9399 3 109.9994 3 109.9605 3 109.9684 3 109.9144 3
DIM20 122.42 0.50 -0.50 122.4417 122.5419 122.4500 3 122.5419 3 122.4979 3 122.5010 3 122.4417 3
DIM21 126 0.50 -0.50 126.2407 126.4399 126.2786 3 126.4399 3 126.2407 3 126.3801 3 126.3533 3
PRODUCTION PART APPROVAL PROCESS (PPAP)
PRICOL
50053028 10/11/2005
CAROLINE HICKEY
23/11/2005
PPAP DOCUMENT NO.:0009-P
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 26/29
PRODUCTION PART APPROVAL PROCESS (PPAP)
VOIDS ✔
PROTRUSIONS ✔
SOLDER COVERAGE ✔
BLISTERS ✔
SCRATCHES ✔
MARKINGS ✔
JAGGED EDGES ✔
OPEN CIRCUITS ✔
SHORTS ✔
CONTAMINATION ✔
SMEARS/SMUDGES ✔
OTHER