minimum process requirements - · pdf filemethods honda requires in applicable manufacturing...

Main Menu Language Screen Previous Menu

Minimum Process Requirements

HSQM-0060 /3 09/30/09

Purpose The purpose of this document is to clarify and communicate minimum process requirements to reduce process related defects.

Scope This procedure applies to all OEM purchased parts and material products

shipped to North American Honda plants. This also includes any component parts shipped to a Tier 1 supplier. This procedure applies to the following processes

Casting Electronics (Printed Circuit Boards) Fluid Fill Heat Treatment Hot Plate Welding Injection Molding Labeling Machining Painting Stamping Torque Welding (Projection, Mig, Resistance)

Wire Harness Please see the MPR Matrix for links to individual MPRs

Minimum Process Requirements Definition

The Minimum Process Requirements define the minimum controls and methods Honda requires in applicable manufacturing processes. These requirements were established to prevent future process related quality defects. These requirements are minimum process requirements. PQ may require additional process requirements where applicable (e.g. Process Inspection Standard).



NM Flow

MPRs Issued via Supplier Quality Manual

RFQ Issued - MPR Requirement Noted

New Model Supplier Kick Off

Packet

Confirm Plan to Meet MPRs

Submit PFMEA / PQCT

Check Compliance with MPRs

Audit Process to PQCT

MPR Process Confirmation Checksheet

NMR 3 / E1 NMR 4,5 / E2

MPR Explanation Letter Mailed to

Suppliers

NAT Issued CPG IssuedPH Operations

NMS PH NMS

Supplier PH NMS

PH NMS

Revise

NMR 2 / E0

Initial Quote The supplier must assure the Minimum Process Requirements are built into

the applicable processes. Requirements must be included when developing each manufacturing process and reflected in the PQCT. The supplier must complete the Minimum Process Checksheet. The quote must include meeting the minimum process requirements as stated in this procedure. NACP is responsible for requesting quotes per drawing specifications. At that time, NACP communicates through the RFQ that the supplier must quote based on meeting the Minimum Process Requirements. If a supplier cannot or will not meet the minimum process requirements, the supplier is required to respond in writing explaining the requirement that they are unable to meet and the reason. This correspondence must be sent to NACP with the part quote. NACP forwards the supplier’s response to PQ. NACP, PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management. The quote may be considered a supplier no quote. Note – If a supplier cannot or will not meet the minimum process requirements, the supplier is required to present how it will guarantee quality.

HSQM-0060 /3 09/30/09



HSQM-0060 /3 09/30/09

NMR3 / E-1 Evaluation

Suppliers are responsible to confirm the Minimum Process Requirements are included in the PQCT before submission to PQ for review. If a supplier cannot or will not meet the minimum process requirement, the supplier communicates concerns to PQ. PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management and NACP is contacted. The supplier is responsible to develop their manufacturing process, incorporating the minimum process controls. Note – the applicable Minimum Process Requirements are included in the PQCT development.

NMR 5 / E-2 Evaluation

At PQ management’s discretion, PQ project members will audit the supplier’s processes to confirm conformance to the PQCT. Any deviations must be addressed immediately. PQ will document concerns on a QAV report when applicable. Suppliers are responsible to maintain adherence to all applicable minimum process requirements during process development and revisions to the PQCT. The MPR Checksheet is used as a tool for confirmation that the minimum process requirements were verified when developing the supplier’s manufacturing process. The check sheets can be found on the Honda website in the Supplier Quality Manual. The website is ‘www.hondasupplyteam.com.” If a supplier does not adhere to the minimum process requirements, PQ communicates concerns to the supplier. PQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management and NACP is contacted. PQ notifies NAT of the supplier’s failure to conform to the minimum process requirements. Failure to comply may result in a supplier class change.

Mass Production

At PQ Management’s discretion, PQ audits the supplier’s processes to confirm conformance to the minimum process requirements. Any deviations found must be addressed immediately. PQ will document concerns on a QAV report when applicable. In the event of a design change to the part, that would impact a MPR requirement, the IPPAAR process must be followed to ensure MPRs are incorporated. It is the supplier’s responsibility to maintain the minimum process requirements.


Casting Minimum Process Requirements

HSQM-0096 Page 1/4 03/12/09


Note: These Minimum Process Requirements apply to both ferrous and non-ferrous casting (including magnesium, aluminum, zinc, etc.) processes.

1. Receiving Inspection (All Casting Types)

Item Method Frequency Ingot identification Each ingot must be individually identified as

to specific material type/grade 100% of material received in ingot form

Raw material properties Confirm Material Data Sheet(s) match required specification(s). Confirmation results to be documented.

Each heat or lot

2. Melting Furnace (All Casting Types)

Item Method Frequency

Raw material traceability

Must record all raw material loaded into each furnace. Must record: furnace identification, material supplier name, material lot number, material bundle or heat number, and date and time of loading.

Each bundle or charge

Temperature of molten material Pyrometer or thermocouple Continuous monitoring

Re-melt percentage

Record % of scrap added. Maximum percentage is to be predetermined and must be able to demonstrate maximum percentage meets material specifications.

Each heat or continuous as applicable

Material properties (chemical analysis, if no holding furnace) Per specification Each heat lot

3. Holding/Casting Furnace (All Casting Types)

Item Method Frequency Temperature of molten material Pyrometer or thermocouple. Material

temperature is to be documented. Continuous or batch as applicable

Pouring temperature (temperature of material immediately before mold)

Must either A) monitor pour temperature automatically or manually or B) be able to demonstrate that the time from removing material from holding furnace until pouring does not allow material to drop below minimum pour temperature. In either case, if material is out of temperature specification, process must stop or material must be returned to holding furnace.

Continuous

Material properties (chemical analysis) Per specification Each heat lot



HSQM-0096 Page 2/4 03/12/09

Casting Minimum Process Requirements (continued) 4. Degassing (If required)

Item Method Frequency Machine settings Record on equipment check sheet. Minimum daily

Gas type/grade Confirm gas certification sheet(s) match specification(s). Results of confirmation to be documented.

Per lot of gas received.

Gas content after degassing Vacuum fusion analysis or Honda approved equivalent

Each heat (batch process) or as agreed with Honda (continuous process)

5. Sand Core/Pattern (Tilt, Low Pressure Die Cast, Ferrous)


Sand properties Confirm certification sheet(s) match specification(s). Results of confirmation to be documented.

Each sand lot

6. Molding (Tilt, Low Pressure Die Cast, Ferrous when applicable)

Item Method Frequency Mold/Die alignment Height gauge, dial indicators, alignment

fixtures, etc. as required As required per preventive maintenance schedule

Machine parameters Record on equipment check sheet Each setup or once per shift otherwise

7. Pouring (All Casting Types)


Pour and cure conditions

Automatic monitoring and control of mold fill speed, pressure curve, cure time, and die clamp pressure (each as applicable for the specific type of casting)

100%

Inoculation/nodularity (ferrous) or grain modifier (non-ferrous)

Confirm structure and chemistry per specification(s) As agreed upon with Honda

Die temperature/flame and cooling rate Automatic control and monitoring 100%



HSQM-0096 Page 3/4 03/12/09

Casting Minimum Process Requirements (continued) 8. Die (All Casting Types)


Die dimensions Die layout and finished parts layout

Prior to mass production approval and for any relevant IPPAAR approvals (die repair, die replacement, etc.)

Die maintenance and repair

Individual cores and cavities are to be uniquely identified and maintained as matched pairs. Maintain individual die history with both preventive maintenance (PM) and reactive maintenance activities recorded

Per PM schedule or as needed.

Part identification

Model/type and cavity number (if applicable) must be built into die so as to identify cast part. Confirm cast part to production schedule.

First piece each setup

Die lube Confirm die lube to material certification sheet

Each setup or once per shift otherwise

Die lube Confirm lube ratio Each mix

Die lube Confirm application pattern Each setup or once per shift otherwise

Die coating Thickness check gauge Per PM schedule or as needed

9. Shot Blast/Tumbling and Vibration (All Casting Types) Note: Shot blasting must be approved by Honda prior to incorporation into the process.

Item Method Frequency Shot size and type Receiving inspection to confirm to data sheet Each lot of shot Shot blast conditions Must control load size, time, and shot speed Once per shift Tumbling and vibration conditions

Must control time parts are subjected to tumbling or vibratory process 100%



HSQM-0096 Page 4/4 03/12/09

Casting Minimum Process Requirements (continued) 10. Quality (All Casting Types) Note: Quotations are to be based on Honda porosity specification. If Honda specification is not available or understood, supplier must ask Honda for direction.

Item Method Frequency Hardness and chemistry (Ferrous and Aluminum Castings)

Confirm by Brinnell Test, SEM, Test lab Spectrometer, Rockwell as applicable. Material specifications to be available at test station. Results to be documented.

Per production lot

Visual defects Visual/Magnaflux 100%

Dimensional check Confirm by coordinate measuring machine (CMM) or QC gages/fixtures. Results to be documented.

At setup or once per shift otherwise

Core dimensional check Confirm by coordinate measuring machine (CMM) or QC gages/fixtures. Results to be documented.

At setup or once per shift otherwise

Mechanical properties Tensile tester Prior to mass production approval and for any relevant IPPAAR approvals

Test capability

Supplier must have capability either in-house or through an outside service provider to conduct destructive testing (e.g. porosity) per specification(s) or other Honda requirement

Prior to mass production approval, for any relevant IPPAAR approvals, and as required by Honda

Test capability

Supplier must have capability (X-ray, eddy current, Magnaflux, etc.) to conduct non-destructive testing per specification(s) or other Honda requirement

As required

Fluid Fill Minimum Process Requirements

Fluid Fill The tables below show the minimum process requirements for Fluid Fill. Minimum Process Requirements 1. Fluid Type


Receiving

Confirm fluid certification meets specifications upon receipt. Record and retain certification per date, time, and storage container number. Record retention policies must be followed.

100%

Refill / Change Out Must have a documented procedure to guarantee proper fluid is delivered to the line after empty fluid container is refilled or changed out.

100%

Fluid Fill Process If a process uses more than one fluid type, the fluid type must be controlled by part number within the program logic.

100%

Supplier must link fluid lot information to part number and be able to trace the barrel or truckload of fluid to a finished product (e.g. If a problem is found outside of supplier and a suspect range needs to be determined).

100%

Fluid Traceability

FIFO procedure and documentation must exist for fluid coming into the facility. 100%

2. Fluid Amount


Final Assembly Fluid amount must be confirmed as a final assembly (e.g. QA machine, Weight). 100%

Part Number Linkage Dispense amount must be controlled by part number within program logic. 100%

Flow Meter If flow amounts are metered, then flow amount must be linked to specific part number by the programmable logic controller (PLC).

100%

Dispensed Amount Dispense amount must be confirmed.

Once per shift and at all changeovers (unless a flow meter is used at fluid fill process)

HSQM-0076 Page 1/3 09/30/09


3. Oil Evacuation (Residual Oil)

Inspection Item Method Inspection Frequency

If residual oil amount is specified by the drawing, the supplier process must have a periodic residual oil amount confirmation.

Negotiate at New Model timing

Residual Oil Confirmation If fluid is used for part testing and oil is drained before shipment, the process supplier must guarantee the method for confirming correct residual oil amount per agreement with Honda (as negotiated during product development).

100%

4. Contamination Control


Contamination Control Confirmation

If contamination amount is specified by the drawing, the supplier process must have method for periodic fluid contamination check.

Negotiate at New Model timing

Child Part Delivery Child parts must meet final assembly contamination standard at delivery to assembly line. 100%

Moisture Level If moisture level in fluid is specified by the drawing, supplier must confirm correct moisture level in fluid.

Each lot / barrel of fluid received

Temporary Use of Caps / Plugs

If temporary caps / plugs are used to seal in fluid until assembled in vehicle, these caps / plugs must meet the contamination and fluid leakage specification. Plug type to be decided at New Model timing.

100%

5. Preventative Maintenance


Filtering System Confirm filtering change frequency per manufacturer recommendations and/or internal study results. 100%

Fluid Life If fluid has a shelf life, supplier must have a method to confirm fluid life and a reaction plan to replace fluid. 100%

Purging / Cleaning Must have a method to purge and/or clean fluid. All changes must be recorded. 100%

HSQM-0076 Page 2/3 09/30/09


6. Leak Confirmation


Final Product Confirmation

Must have a method to test and guarantee the completed system has “no leak” and be able to verify using no good setup parts (e.g. child part leak testing, completed part leak testing, or functional test that will fail if there is a leak in the system).

100%

Leak Test Leak test equipment must be verified by limit master samples to ensure equipment is functioning properly. Each Run

7. Changeover


Changeover Procedure The fluid type and amount must be controlled by part number within the program logic. 100%

Fluid Removal If process uses line-side holding tanks, the supplier must have documented procedure for fluid removal. Each Changeover

Process Confirmation If manufacturing method is not interlocked, supplier must have a documented changeover procedure to guarantee confirmation of fluid fill variation.

Each Changeover

HSQM-0076 Page 3/3 09/30/09


Heat Treatment Minimum Process Requirements

HSQM-0097 Page 1/4 03/12/09


The tables below show the minimum process requirements for Heat Treatment (ferrous and non-ferrous).

1. Receiving Inspection (All Heat Treatment Types)


Raw Material No rust, dents, or abnormal damage per standard. Confirm material certification. Each heat or lot

Parts No rust, dents, or abnormal damage per standard. Confirm lot identification. Each lot

2. Lot Control of Product (All Heat Treatment Types)


Lot Control and Traceability

Heat treated parts must be traceable back to all appropriate processes (raw material, casting, heat treatment, etc.) and meet Quality System Requirements section 7 (Lot Control and Traceability) and HSQM 0028 “Traceability and Lot Control”

Each lot

3. Stacking/Loading Method (All Heat Treatment Types except Induction Hardening)


Basket/Rack/Belt stacking and loading method

A standard, furnace specific loading/stacking method is to be developed during New Model development. Must be able to demonstrate that the standard method produces uniform heat treatment results.

100%

4. Basket/Rack/Belt Requirements (Carburizing and Nitriding Processes)


Basket/Rack/Belt seasoning Must run basket/rack/belt through a minimum of one heat treatment cycle prior to using for mass production

100%



HSQM-0097 Page 2/4 03/12/09

Heat Treatment Minimum Process Requirements (continued) 5. Machine Set-up (Based on New Model development results) Note: An equipment start-up and in-process check sheet is to be created during part and process development and updated throughout mass production. Equipment condition ranges are to be defined via the PQCT and also listed on the check sheet. Minimum Start-up Checks

Anneal, Normalizing,

Neutral-Hardening, Through-

Hardening, and Quench and Temper

Induction Hardening

Flame Hardening

Carburizing and Nitriding Processes (Surface

Hardening/ Carburizing,

Carbonitriding, Nitriding, Ferritic Nitrocarburizing)

Check Item (verified and recorded at start and end of each

lot)

X X Carbon potential verification X X X Temperature Set Point X X Atmosphere controls where applicable X X Time in furnace X X Belt Speed X X Circulating fans (confirm operation)

X X X X Process operating conditions (e.g. flow meters, temperature and pressure gauges) See Note 1 below

X X X X Quench temperatures X X X X Quench concentration X X X X Quench oil type/media X X X X Quench flow/agitation X Coil condition X Energy monitoring (amperage) X Flame condition X X Coil or torch gap and position X X Heat time (actual time heat is on part)

X X X X Delay time before quench X X X X Quench time

Note 1: Analog gauges or meters must have limit marks, digital gauges or meters must show numerical limits.



HSQM-0097 Page 3/4 03/12/09

Heat Treatment Minimum Process Requirements (continued) 6. Process Control Alarms (All types of Heat Treatment)


Operating condition alarms

Must have audible and visual alarms for detection of abnormal conditions for temperature, conveyors, atmosphere flow, circulating fans, and quench parameters. All triggered alarm conditions must be entered in the individual equipment history (see Quality System Requirements, section 11) with cause of alarm and corrective actions taken.

100%

7. Quality Confirmation (All types of Heat Treatment) Note: Supplier must have in-house equipment necessary to perform quality confirmation tests required in the table below. Equipment includes, but is not limited to: appropriate hardness tester(s), microscope, etc. Note: “Drawing” as used below refers to Honda issued or approved part drawing, Honda issued specifications, HES standards, or applicable JIS, ASTM, or other industry specifications. Minimum Quality Checks

Annealing, Normalizing,

Neutral-Hardening, Through-

Hardening, Quench, and

Temper

Induction Hardening

Flame Hardening

Carburizing and Nitriding Processes (Surface

Hardening, Carbonitriding,

Nitriding, Ferritic Nitrocarburizing)

Check Item (Mass production check frequency to be

agreed upon with Honda during part and process development)

Required Required Required Required Surface hardness If specified by

drawing If specified by drawing

If specified by drawing Per Drawing Core hardness

If specified by drawing



If specified by drawing Microstructure




If specified by drawing De-carb, verify layer thickness

Required Required Required Case Depth


If specified by drawing Position of Heat Treatment (macro-etch)

Required (Nitriding

processes only) White layer thickness / diffusion depth




If specified by drawing Mechanical properties

If specified by drawing If specified by

drawing Density (powder metal parts)



HSQM-0097 Page 4/4 03/12/09

Heat Treatment Minimum Process Requirements (continued) 8. Abnormal Process Conditions (All Heat Treatment Types)


Downtime/abnormal condition procedure Must have procedure describing containment of suspect lot(s) and reconfirmation of part quality and furnace condition at re-start

100%

Rework of non-conforming parts

Must conform to Quality System Requirements, section 8.3. Parts may not be reworked without documented approval from each affected Honda facility.

100%

9. Preventative Maintenance (All Heat Treatment Types)


Preventive Maintenance

Must have PM schedule on Thermal couples, Atmosphere controls, Alarms, Fan bearings, Water jackets, Coils, and other recommendations specified by equipment manufacturer

Per Equipment manufacturer's recommendations and standard heat treatment practices or as required by Honda (based on past problems)

Injection Molding Minimum Process Requirements


The following Minimum Process Requirements are required for the Injection Molding processes listed below: Insert, Low Pressure, Dual, Reaction Injection Molding, Gas Assist, Co-Injection.

1. Receiving Inspection


Material confirmation

Supplier must have a documented system to confirm type of material received and identify and confirm critical properties of incoming raw materials. Records of review and confirmation are to be kept.

Each material lot

Traceability Complies with Traceability and Lot Control requirements as defined in the Honda Supplier Quality Manual

Each material lot

2. Material Preparation


Correct Material Must have a documented procedure to confirm correct material is used to mold part and records kept of confirmation

At start of each production lot and each material container change

Re-Grind Control Must have documented procedure to verify percentage of re-grind meets drawing or specification

Start of each re-grind container or production lot as applicable

Material Drying

Must have documented procedure to verify material drying conditions meet the requirements stated per the material data sheet. For hygroscopic materials, must have documented evidence that the required procedure was followed.

Each change of material lot

Material Contamination Must have method to protect material from contamination throughout process (e.g. gaylord with covers, etc.)

Start of each container

Color Concentrate Must have documented procedure to control color concentrate percentage Each production lot

Reactants Confirmation/Correct Formula

Supplier must have documented method (e.g. cupshot weight, rise time, etc.) to determine actual polyol/isocyanate ratio and compare results to standard. Results must be traceable to component lot numbers.

Each material lot change (either polyol or isocyanate)

HSQM-0099 Page 1/3 06/01/10



HSQM-0099 Page 2/3 06/01/10

3. Machine Set-up (Based on New Model development results)

Note: An equipment set-up sheet is to be created during part and process development and updated throughout mass production. Equipment condition ranges are to be defined on the PQCT and transferred to the set-up sheet. There must be a documented procedure to record any deviation from the PQCT and/or set-up sheet.


Insert Low Pressure Dual Gas

Assist Injection Molding

Reaction Injection Molding

Co-Injection

Minimum start up checks:

All checks listed below to be verified at start up and at mold

change

X X X X X X Velocity X X X X X X Hold and pack X X X X X X Injection time X X X X X X Peak pressure X X X X X X Minimum cushion X X X X X X Screw recovery X X X X X X

Injection

Cooling time

X X X X X X Nozzle and heater band (zone) temperature control

X X X X X X Barrel Hot runner (zone) temperature

control, if applicable X X X X X X Theromolator control

X X X X X X Water hook-up control (i.e. color code in and out connections)

X X X X X X X Cavity temperature X X X X X X X Core temperature

X Reactant tank temperature (poly and iso)

X

Mold

Pouring time X X X X X X Opening control X X X X X X Closing control X X X X X X Clamp tonnage X X X X X X Mold position X X X X X X

Clamp

Mold safety control X X X X X X Speed control X X X X X X Position control X Air pressure X

Ejection/ Mold

Fluid/reactant pressure X X X X X X Speed control X X X X X X Hydraulic or Air

Position control X X X X X X X Cycle Time Cycle Time X Gas injection pressure X Speed/ramp control X Time X

Gas Assist

Cylinder position if applicable



HSQM-0099 Page 3/3 06/01/10

4. Molding

Inspection Item Method Inspection Frequency Location of Film/Top coat (Insert / Low pressure / RIM)

Must have method for positively locating film, topcoat, or insert in mold At first piece inspection

Part removal If manual removal, it must be described in an operation standard. Manual or automatic must avoid part damage.

At first piece inspection

Gate Trim Gate trim must not exceed specification or limit sample. Removal of gate must not damage part. 100%

Appearance confirmation Must match drawing, limit sample(s), or other approved guidelines 100%

5. Quality Confirmation Note: Quality confirmation check items are to be verified by an associate independent of the production process.


Quality confirmation check sheet

Must have check sheet which lists items to be verified (check sheet must include harness check for RIM product, durometer)

Created during development

Dimensional confirmation Check fixture, measurement tools, or CMM as defined by Honda Inspection Data Sheet

At start of production lot and one piece each subsequent shift

Color confirmation Qualified visual comparison to master sample or plaque using appropriate and controlled light source

At start of production lot and each color change

Gloss confirmation Per drawing or other specification, master sample, or agreement. Results must be tracked to identify trends.


Appearance Per drawing or other specification, limit sample, or agreement


Leak Test Leak testing is required for parts with testing identified on the spec or drawing



Label Minimum Process Requirements

HSQM-0100 Page 1/2 08/21/08


The tables below show the minimum process requirements for Labeling.

1. Pre-Production


Administrative – Honda Blue Book Requirements (Honda Portal: References; EDI-Barcode Info)

Must have procedure to ensure associate awareness, and must conform to Honda requirements. 100%

Training Must have signed training procedure in place for each process. Associate must clearly understand label operation standards and the consequences of a mis-labeled part.

100%

Production: Operation Standards

Must have signed (by operator and management), updated operation standards in place and posted at each process. Operation standards must address labeling of the part.

100%

Production Schedule Production Schedule to be driven by Honda's EDI data. 100% 2. Process Set Up


Part Confirmation/Component Verification (Poke-Yoke) Confirmation of line set up and all component parts.

At receiving point, prior to line start up,

and at packing point.

Weigh Count (if applicable): Intent is for gross weight to trigger label printing.

Must reset tare weight on scale at every changeover (must have calibration procedures). Part must be verified to meet part SPEC weight.

100%

3. Production


Label Printing: Intent is to tie PLC logic, if available, to the label.

Must automate the creation of container labels using production line (PCL if available) or Demand Management Systems to ensure that the label matches the part. Must generate labels as the last step in the manufacturing process. No Batch Printing of labels. Must have back up printing capabilities with procedures.

100%

Label Application: Intent is for product to be individually labeled at the process with scannable labels.

Old labels must be removed from containers prior to being introduced to production area. Process must allow time to apply individual labels to a container. Label location in compliance with Honda Blue Book Requirements.

100%



HSQM-0100 Page 2/2 08/21/08

Label Requirements (continued) 4. Repack


Stored Parts

Must follow FIFO procedures. Storage location must be clearly identified in all areas (component parts, WIP, raw materials and finished goods). Must practice good housekeeping.

100%

Pick and Pack

Operation Standards must be in place: (clearly defined process procedures) -All partials to be limited to one container -Partials clearly labeled -Accountability / Traceability must be maintained -Completed in a well lit area

100%

Label Application: Intent is for container labels to be printed and applied 1 for 1.

-Must generate paperwork from Honda Requirements -No Batch Printing allowed -Must follow VC2 guidelines for packing parts

100%

5. Shipping


ASN and Master Packing List (MPL) must be created by label data.

Only Mixed / Master and Quick Receive labeling can occur in the shipping area. Procedures must be inn place to ensure that the Master Packing List (MPL) matches container label data.

100%

6. Abnormal

Des

igna

ted

Are

a D

ocum

ente

d Pr

oced

ures

Pa

rt #

ID

Con

tain

men

t R

e-in

trod

uctio

n T

rain

ed

Ass

ocia

tes

Re-

labe

ling

Method Inspection Frequency

Quality Sorts Rework Reject Partial Containers Power Outages Abnormal Packaging System Issues

Business Practices must be in place to control all applicable items during … (all to be included, but not limited to)

100% for all nonconforming parts


Machining Minimum Process Requirements

HSQM-0101 Page 1/2 03/12/09


These requirements apply to both machining and grinding processes.


1 Process capability (machined dimensions and surface roughness)

Must be able to demonstrate process capability (Cpk or Ppk) of 1.33 for each machine/fixture as negotiated with each applicable Honda plant (including sampling plan and sample size)

Prior to mass production approval and for any relevant IPPAAR approvals

2 Measurement datums and critical dimensions

Per drawing, unless otherwise agreed upon by supplier and Honda

During new model development (prior to trial part submission) and for any relevant IPPAAR approvals

3 Machining/fixturing datums Per drawing, unless otherwise agreed upon by supplier and Honda

During new model development (prior to equipment/fixture specification) and for any relevant IPPAAR approvals

4 Tool life (including grinding wheel dressing)

Must be able to demonstrate that tool change and grinding wheel dressing frequencies have been determined by a study of wear and performance characteristics. Results are to be available to Honda upon request.

A tool life study plan is to be created by the supplier and approved by Honda during new model development and for any relevant IPPAAR approvals

5 Equipment/machine adjustment

Equipment purchased or refurbished after April 1, 2009 must use electrical or mechanical system (e.g. lockout, password, key, etc.) to prevent unauthorized or inadvertent machine adjustment

100%

6 Broken tool/tap/drill/grinding head

Equipment must have automated system and/or a Honda approved process step to detect broken tool/tap/drill/grinding head

100%

7 Part position

Equipment/fixturing must assure part presence and proper position (no mislead or mis-chuck) during machining (e.g. use of positive air flow sensor or seal, proximity sensors, laser sensors, vision system, etc.). Part presence or part position failures must be alarmed and prevent the equipment from continuing the process.

100%



HSQM-0101 Page 2/2 03/12/09

Machining Minimum Process Requirements (continued)


8 Machine/fixture identification mark

A marking unique to each machine and fixture must be placed on each part produced in duplicate processes (i.e., two or more machines producing the same part). Honda must approve the marking and location on the part.

100% (Marking and location are to be approved before mass production and for any relevant IPPAAR approvals)

9 Correct part loading

Fixture must have model/type variation detection or poka yoke when machine and/or fixture is used for more than one model/type product (e.g., right hand versus left hand drive or manual versus automatic transmission)

100%

10 Correct fixture/program

Unless dedicated to a single part number, equipment purchased after April 1, 2009 must automatically detect any mismatch between the fixturing and machine program selected. Any mismatch must be alarmed and prevent the equipment from continuing operation.

100%

11 Periodic quality checks

Confirmation of critical quality characteristics (variable data to be recorded and analyzed for trends)

Beginning, middle, and end of each shift and after changing to a different model/type variation or as agreed to by Honda

12 Threaded hole quality

Major thread diameter and pitch to be verified with thread gauges (go and no go). Minor thread diameter to be confirmed with plug gauge.

Beginning, middle, and end of each shift; after tool change; and after changing to a different model/type variation; or as agreed to by Honda

13 Contamination Parts must be free from contamination that could impact the function of the part or the function of a mating part(s)

100%

14 Double cycled parts

Equipment purchased after April 1, 2009 must detect uninterrupted part presence to prevent double cycle operation (part presence must be interrupted, i.e., part is removed and new part placed before subsequent machine cycle begins)

100%


Painting and Powder Coating Minimum Process Requirements

Painting and Powder Coating Minimum Process Requirements 1. Environmental, Health, and Safety


Environmental, Health and Safety Must be able to provide documentation showing current conformance to all local, state, and federal standards

Upon request

2. Pre-production Development


Fixture/rack design Must be able to demonstrate that painting fixture/rack design and quantity are able to meet quality and capacity requirements

Upon request

Paint application

Must be able to demonstrate confirmation of proper coverage, robot programming (if applicable), spray pattern, repeatability, color development, and part dimensional effects prior to mass production part approval

Upon request

Catalyst storage Per manufacturer recommendations. If using a continuous/proportioning system, catalyst storage to have inert blanket

100% as applicable

Inspection lighting Must conform to HES D2018, HES D2016 and/or part specification. All lighting must be maintained.

Per lighting manufacturer’s recommendations



Raw material (solvents, catalysts, paint, additives, etc.)

Each container is to be identified with material and lot number linked to manufacturing date. Confirm Certification Sheet meets required specifications.

Each material lot

Pre-ship spray out (where color plaque has been issued or approved by Honda)

Unless the lot has been approved by Honda, each paint lot pre-ship sample/plaque must be verified to standard color plaque by paint manufacturer and painting facility. Records must be kept of verification.

Each material lot

Received parts Visual inspection for general defects (burrs, scratches, dents, deforms, flash, etc.) 100%

HSQM-0102 Page 1/7 03/12/09



Painting and Powder Coating Minimum Process Requirements (continued) 4. Production


Traceability Minimum range to range traceability and must conform to the Traceability and Lot Control procedure (per Honda Supplier Quality Manual – HSQM-0028)

Each production lot

Material storage is to conform to manufacturer’s recommendations and local, state, and federal standards. Material usage must conform to First In First Out (FIFO) requirements as described in section 6.2 of the Honda Supplier Quality System Requirements.

Material storage (includes new materials and in-process materials) Materials that exceed manufacturers expiration date must be

re-certified by the paint manufacturer prior to use in production.

100%

Must have documented procedures for paint mixing and operation of mixing system. Procedures must identify paint/catalyst percentages, and other variables.

Each mix

Temperature and humidity of the mix area must be recorded Each mix sheet Paint mix system

Must have positive air pressure within paint mixing area compared to surrounding area(s) 100%

Must have documented procedure to avoid contamination and part damage (e.g. wearing gloves, no silicone, etc.) 100%

Part loading process Operation standard for part loading process must include visual aid(s) for correct part orientation, masking, rack identification, etc.

100%

Part preparation and pre-treat

Must have part preparation and/or pre-treat system in place and maintained, prior to painting process. Must conform to applicable Honda and/or manufacturer’s specifications. Parts must not be handled after preparation process (unless approved by Honda) and clean environment must be maintained until painting.

100%

Primer/adhesion promoter application (if applicable)

Must conform to applicable Honda and/or manufacturer’s specifications. 100%

Flash off tunnels / Oven Must conform to applicable Honda and/or manufacturer’s specifications. 100%

Color application Must conform to applicable Honda and/or manufacturer’s specifications. 100%

HSQM-0102 Page 2/7 03/12/09



HSQM-0102 Page 3/7 03/12/09

Painting and Powder Coating Minimum Process Requirements (continued) 4. Production (continued)


Conventional painting

Electro-static

Powder painting


Purging of paint lines and application equipment

Must have documented procedure for purging method

Each material/color change

Flow rate Volume/Mass per time check

Manual System - Each material change or material lot change, or twice per shift otherwise PLC Continuously Monitored System- Manual Confirmation once per month

Atomization Verify and record equipment settings

Each material change or material lot change, or twice per shift otherwise

Viscosity Check per specification

Each mix or addition (circulation systems) or each 2 hours (pressure pots)

Set up sheet Record spray associate (if applicable), lot numbers, equipment settings, etc.

Each shift or production lot change

Spray pattern Verify spraying technique (if applicable) and verify and record equipment settings

Each production lot change, each change of spray personnel, or 4 times per shift otherwise

Gun distance Verify spraying technique (if applicable) and verify and record equipment settings

Each production lot change, each change of spray personnel, or 4 times per shift otherwise

Booth environment

Verify and record booth temperature, humidity, air balance, conveyor speed, etc.

At beginning, middle, and end of shift

Proper coverage/ appearance

Visual at process First piece of each production lot or other change

Verify and record oven temperature settings and actual temperatures

Every 2 hours and at temperature setting change

Oven parameters Data pack or equivalent to verify

part temperature achieves required cure parameters

Each temperature change, daily, or unless otherwise specified

Flash off between booths

Per paint manufacturer’s recommendations

At material or line speed change

Primer

Part Charging Verify system charge setting per part/system specification Each part/color change



HSQM-0102 Page 4/7 03/12/09




Electro-static

Powder painting











Set up sheet Record spray associate (if applicable), lot numbers, equipment settings etc.



Each production lot change, each change of spray personnel, of 4 times per shift otherwise


Each production lot change, each change of spray personnel, of 4 times per shift otherwise

Booth environment



Proper coverage/ appearance

Visual at process First piece of each production lot or other change



Oven parameters Data pack or equivalent to verify part

temperature achieves required cure parameters



Per paint manufacturer’s recommendations


Base Coat




HSQM-0102 Page 5/7 03/12/09




Electro-static

Powder painting











Set up sheet Record spray associate (if applicable), lot numbers, equipment settings, etc.



Each production lot change, each change of spray personnel, or 4 times per shift other wise


Each production lot change, each change of spray personnel, or 4 times per shift other wise

Booth environment



Proper coverage/ appearance Visual at process

First piece of each production lot or other change



Oven parameters Data pack or equivalent to verify

part temperature achieves required cure parameters



Per paint manufacturers recommendations


Top Coat




HSQM-0102 Page 6/7 03/12/09


Unloading of part Must have procedure to avoid part damage (e.g. scratches, dents, deforms, etc.)

100%

Inspection lighting Must conform to HES D2018, HES D2016 and/or part specification. All lighting must be maintained

Per lighting manufacturer’s recommendations

Part Inspection Must have method to record and track identified part defects 100%

5. Quality Confirmation


Color

Visual against Honda approved standard (a colorimeter/spectrophotometer may be used to help analyze or track the color position but final judgment is visual against approved standard. Note: auto body color parts may specifically require X-Rite tracking (if part size allows).

Beginning and end of each color run and/or part/equipment setting change

Color

Color judgment is to be made only by qualified individuals. Qualification is to include passing the Munsell 100 Color Acuity test, Ishihara colorblindness test, and ability to use colorimeter or spectrophotometer and interpret results.

All relevant associates

Color

Supplier must have immediate access to colorimeter/spectrophotometer and Macbeth or equivalent light simulating specified light requirements for color judgment.

100%

Gloss

Gloss meter per Honda specification. Results are to be documented and tracked. If part configuration does not allow use of gloss meter, visual against Honda approved master standard.

Beginning and end of each color run and/or part/equipment setting change

Visual defects Per Honda specification or Honda approved limit sample 100%

Adhesion, Film build, Hardness, Xylene (Or other specified chemical) resistance

Per applicable Honda / Paint Manufacturer specification

Each production lot

Complete specification testing Per Honda specification

Prior to mass production part approval and upon request



HSQM-0102 Page 7/7 03/12/09

Painting and Powder Coating Minimum Process Requirements (continued) 5. Quality Confirmation (Continued) Special Quality Confirmation Requirements for Painted Torque Surfaces Note: Unless specifically waived by Honda, the following requirements apply to all painted surfaces that will bear a threaded fastener (e.g., bolt or nut) torque load. Additional requirements may be found in the Minimum Process Requirement – Torque section of the Honda Supplier Quality Manual. Torque relaxation (Tension relaxation)

Torque relaxation study to be conducted before and after performance testing

Prior to mass production part approval, with any relevant IPPAAR and upon request

Paint thickness Determine and record minimum and maximum thickness per applicable Honda specification

Each production lot

Paint adhesion HES D6501 or other applicable specification

Each production lot

Coefficient of friction Digital static and kinetic friction tester

Prior to mass production part approval, with any relevant IPPAAR and upon request

Heat impact Elevate to required temperature. After cooling, conduct torque relaxation study

Upon request by Honda

6. Rework


Re-Paint

Repaint is normally allowed one time unless otherwise approved by Honda. Additional repaints may be allowed for certain parts and materials and are to be determined prior to mass production part approval. Regardless of the number of repaints: all parts must meet dimensional, coating, and other specifications; must be the same color over color; and part must be identified as a repaint for each time repainted.

All repaints

7. Maintenance


Rack Maintenance

Racks are considered to be equipment and subject to the requirements of the Quality System Requirements and the General Minimum Process Requirements

100%


PCB Minimum Process Requirements

HSQM-0103 Page 1/8 03/12/09

Electronics – PCB Minimum Process Requirements

The tables below show the minimum process requirements for Printed Circuit Boards (PCBs).

Note: Products using lead/lead free solder must conform to latest revision of IPC-A-610 (Association Connecting Electronics Industries). Note: If both leaded and lead free solder process/materials are used in a facility, Honda notification and pre-approval is required. Scan or visual controls must exist to prevent mixing of Lead & Lead Free components, materials, and tools. 1. Manufacturing Facility

Item Method Frequency Environmental Controls Soldering facility must be enclosed with

controlled temperature & humidity. 100%

Cleanliness

Controls must exist that prevent contamination or deterioration of soldering tools, materials, and PCB surfaces to be soldered.

100%

2. Component and Material Storage and Handling

Item Method Frequency Flux Must control flux properties

per Material Data Sheet 100%

Solder paste Must control solder paste properties per Material Data Sheet

100%

Moisture sensitive components (IC�’s, etc)

Per J-STD-033B for surface mount devices and IPC9503 for non-IC components 100%

Lead versus Lead Free solder components and materials

Scan or visual controls must exist to prevent mixing of Lead & Lead Free components and materials.

100%

Open PCB and component packaging

Regardless of location, PCB and component packaging must be stored/packaged in an environment that is free from risk of oxidation and contamination that negatively impacts solderability

100%



HSQM-0103 Page 2/8 03/12/09

PCB Minimum Process Requirements (continued) 3. Solder Paste Printing

Item Method Frequency Must measure solder paste height on sample of smallest pads across PCB. Comparison measurements to be done across PCB to guarantee even distribution from board to board. Recommended best practice is to do to a volume check once per shift along with the height check.

Once per 2 hours Solder paste volume and distribution

Controls must exist for critical parameters, such as squeegee material, angle, pressure, speed, stroke, under board support, etc.

100%

Post print inspection 2D inspection required for all PCBs with fine pitch ( 0.025 in) ICs and BGAs (Ball Grid Array)

100%

Stencil cleaning method Automatic stencil cleaning equipment to remove all excess solder paste. Must be inspected upon completion of cleaning.

Once per shift and each product change

Stencil manufacturing method Must be laser cut or electroformed (E-FAB) Each stencil Stencil underside wiping Must have automatic underside wiping Per supplier specifications

Solder paste run-out material If reusing solder paste run-out, must perform a kneading cycle

Per supplier specifications (minimum once per 4 hours)

Stencil print registration Vision system alignment with fiducial. 100%

Stencil print registration capability

Must be able to demonstrate ongoing CpK of 1.33 or better by measuring smallest component pads from actual product

Prior to mass production (initial at T-3 trial build) ,for any relevant IPPAAR approvals, and after any event that affects print registration



HSQM-0103 Page 3/8 03/12/09

PCB Minimum Process Requirements (continued) 4. Component Placement


Must be able to demonstrate ongoing CpK of 1.33 or better for smallest component, finest pitch IC, BGA, and any other component requested by Honda

Prior to mass production (initial at T-3 trial build) ,for any relevant IPPAAR approvals, and after any event that affects placement accuracy

Placement capability (each machine, whether in series or parallel)

Controls must exist for critical parameters, such as nozzle vacuum, placement stroke, pressure, speed, under board support, etc.

100%

Ensure correct component when changing reel/tray

Bar code scan system or 100% documented confirmation by both install operator and supervisor or designee

Each setup for product change and each replenishment of a reel or tray

Component Registration Vision system alignment with fiducial. 100% Manual placement of SMT components

No Manual placement of component prior to reflow unless approved by Honda 100%

5. Manual/Mechanical Insertion of Through-Hole Components

Item Method Frequency Confirmation of correct component and placement

Visual confirmation of correct component and polarity 100%

Damage to other PCB components

Controls must exist to ensure no damage to other components during insertion (e.g. tools, fixtures, etc.)

100%

6. Reflow


Thermal Profile

Based on component, board, glue, and solder specifications, a standard thermal profile is to be created prior to mass production for all PCB types. Must be able to demonstrate that subsequent periodic profiles meet standard profile.

Each oven setting change or once per week unless monitored by an Automatic Continuous Monitoring System

Thermal couple measurement

Must notify Honda of locations during NM timing. Honda may choose to set location requirements if necessary. Measurement areas on PCB to account for uneven heating across board (e.g. due to component density, EMI shields, or other thermal masses on PCB).

During NM timing or any applicable design changes



HSQM-0103 Page 4/8 03/12/09

PCB Minimum Process Requirements (continued) 7. Glue Dispense and Cure


Glue dot diameter Must be able to demonstrate ongoing CpK of 1.33 or better

Prior to mass production (initial at T-3 trial build) and for any relevant IPPAAR approvals

Glue dot placement Must be able to demonstrate ongoing CpK of 1.33 or better for smallest glued component


Thermal profile

Based on component, board, and glue, a standard thermal profile is to be created prior to mass production for all oven types. Must be able to demonstrate that subsequent periodic profiles meet standard profile.

Each oven setting change or once per week

Thermal couple location





HSQM-0103 Page 5/8 03/12/09

PCB Minimum Process Requirements (continued) 8. Solderwave/Selective Solder


Thermal Profile

Based on component, board, and solder specifications, a standard thermal profile is to be created prior to mass production. Must be able to demonstrate that subsequent periodic profiles meet standard profile.

Each setting change that affects temperature or once per week otherwise

Thermal couple location



Flux Coverage

Dip application or manual application process not permitted in production. Must create coverage standard. Check spray or bubble application test piece (paper) to standard.

At start of each production shift and each setting change

Flux Analysis Test must be performed to confirm Technical Data Sheet requirement (e.g. titration, PH, specific gravity, other approved method)

Closed systems: Once per week or when flux is added to ensure no contamination Open systems: Once per shift or when flux is added

Solder pot analysis Perform composition and contamination analysis. Modify / replace / replenish solder per analysis.

Per supplier specifications

Solder pot dross Dross must be controlled. Determine dross removal frequency per usage. Per supplier specifications

9. Hand Soldering

Item Method Frequency Hand soldering not permitted for mass production

Other than off line repair or touch-up, hand soldering not permitted

Not permitted

10. Conformal Coating

Item Method Frequency Conformal coat application method

Automatic spray, dispense or automatic dip. Manual application or brushing (manual or automatic) not permitted

100%

Conformal coating coverage �‘Black light�’ or template as applicable. Must create coverage standard

At start of each production shift and each setting change

Cure Profile

If using a curing oven, a standard thermal profile is to be created prior to mass production. Must be able to demonstrate that subsequent periodic profiles meet standard profile.

Per supplier specifications



HSQM-0103 Page 6/8 03/12/09

PCB Minimum Process Requirements (continued) 11. In-Process Handling

Item Method Frequency PCB storage for work in progress (WIP) when not on conveyer

Any storage racks must hold PCB by an unpopulated tab and not allow any contact to components or solder joint areas

100%

PCB flexure, at any process in which the PCB is engaged or could be flexed

Must be able to demonstrate (normally through strain gauge analysis per IPC9704) that normal process and process handling does not damage the board, solder joints, or components.


Electro Static Discharge (ESD) control

Conform to the latest revision of ANSI/ESD S20.20 100%

Material storage control (including storage, in process, and finished goods of flux, solder paste, and moisture sensitive components such as ICs and others)

Per material or component technical data sheet 100%

PCB Components damage

Components on PCB must not be contacted during all in-process handling and or transfer equipment unless specified in the process. Controls must exist to ensure no damage to components (example: tools, fixtures, guides, etc.)

100%

PCB Contamination

Must have sufficient controls to prevent PCB contamination due to manufacturing environmental, equipment, etc. No skin contact to PCB allowed (Glove or finger cots (Per IPC A610))

100%

Flux handling Containers must be controlled and clearly identified in order to maintain MDS specifications

100%

12. Panel Separation


De-paneling or separation method

Use of rotary cutter, router, or other method approved by Honda. Manual breaking not permitted. Reference 11.2 for flexure analysis.




HSQM-0103 Page 7/8 03/12/09

PCB Minimum Process Requirements (continued) 13. Screw Insertion


Screw torque Must comply with Torque Minimum Process Requirement

Must comply with Torque Minimum Process Requirement

Screw presence (no missing screws)

Presence is counted when torque and angle are achieved. Parts must be prevented from proceeding to next process station until proper count is achieved or must have secondary process to confirm screw presence.

100%

Manual screw insertion PCB must be protected by product design or fixture from potential damage by insertion device

100%

14. Test


Test coverage by component

Must create a matrix that shows verification of part presence, proper polarity, and value for each component by test process (AOI (Automatic Optical Inspection), ICT (In-line Circuit Test), functional test, final inspection, etc.). Any incomplete detection items must be agreed to by Honda

Prior to mass production and any relevant design change

Test coverage by function

Must create a matrix that shows capability of detection of all functions per spec by test process (functional test, final inspection, etc.). Any incomplete detection items must be agreed to by Honda

Prior to mass production and any relevant design change

Case grounded (if conductive) at Final Test Per process design 100%

Part connector terminal condition

Controls must exist to prevent damage to pins/terminals (bent, spread, etc.) after engagement of connector or pins. Alignment gauge recommended.

100%

Test equipment connector condition

Ensure no damage to tester (ICT, Function, Burn in, etc.) pins/terminals (bent, spread, etc.)

At set up and change over

Test equipment connector pins/terminals

Ensure tester pins/terminals, alignment, and contact surface/area meet circuit current ratings (ICT, Function, Burn in, etc.). Ensure correct pin dimensions.

To be confirmed at new model timing and when PM is performed



HSQM-0103 Page 8/8 03/12/09

PCB Minimum Process Requirements (continued) 15. Repair/Rework

Item Method Frequency Rework control Conform to IPC-7711 100% Repair control Conform to IPC-7721 100%

Repair materials Repair materials (flux, solder, conformal coat, etc.) must be the same as used in mass production

100%

Liquid Flux Analysis Test must be performed to confirm Technical Data Sheet requirement (e.g. titration, PH, specific gravity, other approved method)

Once per shift or when flux is added


Plastic Fuel Tank ‘Hot Plate’ Welding Minimum Process Requirements

HSQM-0098 Page 1/4 03/12/09

Plastic Fuel Tank ‘Hot Plate’ Welding Minimum Process Requirements The following Minimum Process Requirements are required for ‘hot plate’ welding of critical parts/components (e.g. fire/safety regulation parts including fill neck on plastic fuel tanks). 1. Receiving Inspection


Material confirmation

Supplier must have a documented system to confirm type of material (resin) received and identify and confirm critical properties (including melt flow index) of incoming raw materials. Test sample(s) must be taken by molding/welding supplier directly from resin shipping container. Records of review and confirmation are to be kept.

Each material lot

Traceability

Complies with Traceability and Lot Control requirements as defined in the Honda Supplier Quality Manual. (All through-hole welded components are to be treated as range to range as described in Traceability and Lot Control section of Honda Supplier Quality Manual).

Each material lot

2. Equipment


Time, temperature, and pressure control settings

Critical parameter set points to be established and listed on PQCT and subject to IPPAAR approval for changes. Critical parameters to include, at a minimum: hot plate temperature; matching time; matching pressure; heating time; heating pressure; change-over time; joining (fusion) pressure; and cooling time. Must be verified and recorded through operator check.

Start of shift or product change

Fail-safes

The critical parameters (listed above) must be automatically monitored. Critical temperatures must be monitored by redundant thermocouples. If any critical time, temperature, or pressure is detected outside of specified range(s), equipment must stop processing and, unless otherwise agreed to by Honda, positively destruct abnormal part.

100%

Equipment Adjustments Must have lockout to prevent unauthorized adjustment of machine conditions. 100%



Plastic ‘Hot Plate’ Welding Minimum Process Requirements (continued) 3. Process Controls


Flatness of mating area on main body (e.g., fuel tank shell)

Flatness requirement to be specified on PQCT and automatically monitored and recorded. 100%

Component part positioning (including perpendicularity/parallelism/angularity)

Controlled during all phases of welding process. Method of control to be agreed upon with Honda.

100%

Component part positioning and flatness capability

Must be able to provide quantifiable/variable data and/or trends that confirm current production conforms to all specifications

Upon request

Process fixture identification

The finished product is to be uniquely identified (i.e. serial numbered), and the base part molding cavity, weld fixture, and cooling fixture identification are to be traceable for each finished product (only cavities and fixtures potentially affecting critical weld(s) need to be traceable).

100%

Dimensional stability (prior to welding)

Base parts and components to be welded must come to and remain at process line ambient temperature prior to welding. Minimum time to achieve ambient temperature to be determined during new model development and agreed upon with Honda.

100%

Thermal decomposition

All process parameters must be controlled to prevent thermal decomposition of welded materials. Critical temperatures to be monitored by redundant thermocouples.

100%

Head travel distance

Hot plate/component part head travel distance must be controlled by linear potentiometer or LVDT (Linear Variable Displacement Transducer)

100%

Hot plate heating surface condition Must be kept free of contamination (e.g. grease, decomposed plastic, etc.) and in good condition

100%

4. In Process Inspection


Weld integrity

Weld integrity is to be confirmed by visual check for ‘double bead’ and leak check of a type and duration to be agreed upon with Honda. A method must be used to show successful completion of checks and shown on part (by marking) or tied to serial number.

100% or as required

HSQM-0098 Page 2/4 03/12/09



HSQM-0098 Page 3/4 03/12/09

Plastic ‘Hot Plate’ Welding Minimum Process Requirements (continued) 5. Quality Confirmation Note: Quality confirmation check items are to be verified by an associate independent of the production process.


Weld quality

Must use Microtome analysis to confirm melt depth, melt thickness, and displacement with control limits to be agreed upon with Honda. Must be able to demonstrate weld process consistently meets control limits. Microtome data to be analyzed over time for trends.

Each set up or changeover and, additionally, as agreed upon with Honda.

Weld quality

Microtome analysis to be done on all critical welds. Measurement method to be established with Honda, however, a minimum of four samples with 90 degree separation between each is required; ‘averaging’ of data not allowed. Microtome slides to be retained 6 years.

Each set up or changeover and, additionally, as agreed upon with Honda.

Weld quality

Whole component pull test. Main body or component part to fail before weld. Pull force data to be recorded and tracked for trend analysis. Pull force lower control limits to be established with Honda during new model development.

Start of each shift and at each other first piece confirmation

Weld quality

Pry/flower/fan test (cross sectional tensile and bend tests). A minimum of eight cuts with 45 degree separation between each is required.


Component part concentricity to applicable feature (e.g. bored hole) on mating part

Confirm by destructive test (pin/microtome) and visual inspection. Component part original footprint must be 100% located on main body original footprint (melt pad extended bead is not considered part of original footprint for either component part or main body). See diagram 1 (next page).




Plastic ‘Hot Plate’ Welding Minimum Process Requirements (continued)

Main Body

Component

Melt Pad

Extended bead

Diagram 1

Extended bead

HSQM-0098 Page 4/4 03/12/09


Stamping Minimum Process Requirements

HSQM-0104 Page 1/3 03/12/09

Stamping Minimum Process Requirements 1. Material Ordering Confirmation


Confirmation of ordering correct material type, grade, and thickness from approved source if required by Honda

Verify Purchase Order/Material Supply Application (MSA) directly to all current drawing(s) specifications. Verification to be recorded.

Each material order (not each release)

2. Material Inspection


Confirmation of receiving correct material type, grade, and thickness

Material shown on the Material Certification Sheet must be confirmed to the Purchase Order/MSA information. Verification to be recorded and a copy of the Material Certification sheet retained.

Each coil

Yield, tensile, and elongation properties/test results shown on Material Certification Sheet must be confirmed to material specifications required by the drawing(s). Confirmation to be recorded. Additional or other property confirmation checks may be required by Honda.

Each coil prior to use

Confirmation of material properties

Material thickness to be measured and confirmed to material specifications required by the drawing(s). Confirmation to be recorded. Additional physical confirmations may be required by Honda.

Each coil prior to use

3. Blanking or Stamping Process Set up


Set Up Procedure

Supplier must have a documented press and tool/die set up procedure(s). Set up results (e.g. shut height, lead check results, cushion pressure, etc.) must be documented. Beginning/end of coil & misfeed procedure must exist.

At each production lot and coil change



HSQM-0104 Page 2/3 03/12/09

Stamping Minimum Process Requirements (Continued) 4. Process Control


Part/Tool/Equipment Safeguards

Must have systems/safeguards in place and approved by Honda to prevent damage to tool/die/equipment. Specific automatic systems to detect malfunctions may be required by Honda.

At each production lot

Part Quality

Supplier and Honda must agree on devices, fixtures, and systems to be used to assure proper part quality, especially positioning, throughout all stamping steps

Prior to mass production approval and for each relevant IPPAAR approval

All lubricants must be approved by Honda to prevent contamination to Honda’s paint system

Prior to mass production approval and for each relevant IPPAAR approval Lubrication Finished product shall not be stored or shipped

with excess lubricant that may lead to a safety or quality concern

100%

Rust or Contamination

Product is to be shipped free of rust and contamination and received at Honda free of rust and contamination. Any rust preventative(s) must be approved by Honda prior to use.

100%



HSQM-0104 Page 3/3 03/12/09

Stamping Minimum Process Requirements (Continued) 5. Quality Confirmation


Part Dimensional Checks

Measurement by inspection fixture, coordinate measuring machine, etc. (specific method may be specified by Honda). Inspection data must be documented.

Beginning and end of each production lot unless otherwise specified by Honda

Wrinkles, Folds, and Cracks

Must have visual inspection for wrinkles, folds, cracks, necking, or other defects. Wrinkles in non-mating and non-critical areas may be allowed with prior approval by Honda. In this case, limit samples must be created by the supplier and approved by Honda.

100% unless otherwise agreed to by Honda

Burrs

Must have visual inspection for burrs. Burrs must not be detrimental to the product (safety or function of part or appearance of final product)

100% unless otherwise agreed to by Honda

Material thinning

Measure by micrometer or equivalent. Location(s) and method to be approved by Honda. Thinning not to exceed 25% of nominal material thickness unless otherwise specified by Honda. Results to be documented.

Beginning and end of each production lot unless otherwise specified by Honda

Master Part

The supplier must retain a master part and be able to demonstrate that it meets all drawing specifications, or provide a continuous improvement plan for all areas that do not meet the drawing specification. Supplier shall follow Honda SQM requirements for nonconforming parts. The master part shall be identified with part name, part number, design change level, name of approver, and date of approval.

Prior to mass production approval and for each relevant IPPAAR approval

Inspection Markings

Any markers, pens, or similar items used to mark parts must be approved by Honda to assure compatibility with Honda’s paint system(s)

100%


Torque Minimum Process Requirements

HSQM-0105 Page 1/1 03/12/09

Torque Minimum Process Requirements

The table below shows the minimum process requirements for torque.

Notes: 1) The Torque Minimum Process Requirement does not apply to plastic fasteners or self-tapping screws with no specified toque value. 2) The process rank (A, G, B, or C) is determined by the potential failure of the specific fastener/joint - not the part or drawing rank:

A Rank Process – process failure results in a problem that leads to sudden loss of vehicle function; such as cannot turn, stop, go or loss of safety features. G Rank Process – process failure creates a non-compliance to government regulations. B Rank Process – process failure results in product performance impairment, not related to safety or government regulations. C Rank Process – process failure creates an appearance or non-functional dimensional variance. A C rank process that includes a fastener of 8mm or larger must meet the same requirements as a B Rank Process.

Requirement A/G Rank Process

B Rank Process

C Rank Process

Use electronic torque equipment and be able to demonstrate a CpK of 1.33 or greater Must Want Want Manual torque equipment and electronic torque equipment without a demonstrated CpK of 1.33 or greater must use a secondary process to confirm (not set) torque

N/A Must Want

If electronically controlled equipment is used, it must have both visual and audible alarms in the event target parameters are not achieved ( e.g. torque, angle, height).

Must Must Want

The process which applies initial torque cannot be the process to confirm the torque. The initial torque must be within tolerance. N/A Must Want Equipment/jig/fixture will not release/advance part to the next process unless torque is confirmed Must Want Want Equipment must measure and confirm clamp load by angle and/or height data. Time to torque may be used only to indicate torque unable to be achieved.

Must Want Want

Each assembly must be uniquely identified and linked to its own critical data (torque and angle or height) Must Want Want Shift start up checks must include, but are not limited to, verification of process controls (e.g. preset wrenches, alarms, and poka-yokes) Must Must Must Product confirmation must be done at the beginning/middle/end of each shift and before and after each changeover. Additional confirmation is required for abnormal situations.

Must Must Want

Product torque must be confirmed a minimum of once per week by Quality department (non-production department). Additional confirmation(s) is required for abnormal situations.

Must Must Want

If Off-line Repair exists, area must have same torque equipment as On-line process Must Want Want


Weld Minimum Process Requirements

HSQM-0106 Page 1/4 03/12/09


These Minimum Process Requirements apply to processes using resistance welding, projection welding, and metal-inert gas (mig) welding for steel applications.

1. Equipment

Resistance Welding

Projection Welding

Mig Welding Item Method Frequency

Tip dress and tip change frequency

Must be able to demonstrate that tip dress and tip change frequencies have been determined by a study of wear and performance characteristics

Upon new equipment installation; tip style, composition, or manufacturer change; material grade/thickness change; and/or during new model development

Nozzle condition

Confirm correct nozzle diameter and nozzle cleanliness

Start of each shift or as required by Honda

Automatic

Mig Welding

Equipment controls

Equipment must have lockout to prevent unauthorized weld parameter adjustment

All Equipment

Automatic

Mig Welding

Weld Failure or Interruption

Must have visual and audible alarm for a detected weld failure 100%

Automatic Equipment

Automatic Equipment


Equipment must not release or advance part to next station in the event of a welding process failure or if the equipment cycle is not completed

100%

Manual

Lines and Equipment

Manual Lines and Equipment


Equipment using a Programmable Logic Controller (PLC) must stop in the event of a welding failure

100%

Adjustments

Adjustments made to the process must be documented and the quality characteristics of all affected welds must be confirmed

At each jig or fixture change, robot programming change, weld parameter adjustment, etc.

Automatic Equipment

Automatic Equipment

Automatic Equipment

Component Part Presence

Equipment must have part presence and type poke yoke/sensor(s)

Sensor to be verified at the start of each shift and (unless same sensors used) at each part number change

n/a n/a Nut Presence Equipment must have sensor/poke yoke for presence and proper orientation

Sensor to be verified at the start of each shift and (unless same sensors used) at each part number change



HSQM-0106 Page 2/4 03/12/09

Welding Minimum Process Requirements (continued) 1. Equipment (continued)

Tip Dressing Tip dress blade/tool to be inspected and replaced prior to wear affecting dress capability

Start of each shift

Automatic Equipment

Automatic Equipment

Automatic Equipment Tip Dressing

Must have automatic tip dresser. Tip dress failure must alarm and/or stop equipment

All equipment




Tip Dressing Must have cycle counter with alarm to indicate when tip is to be dressed

All equipment

Spot weld illustration

Supplier to create illustration or drawing identifying weld location and robot application

To be created prior to Mass Production part approval and maintained as long as part is produced

Mig weld illustration

Supplier to create illustration or drawing showing mig weld locations and minimum lengths

To be created prior to Mass Production part approval and maintained as long as part is produced

Datum Targets

Must have datum targets on all welding jig bases, inspection fixtures, and included in jig and fixture standards

100%, confirmed at NM start-up and used during all jig modifications and/or adjustments

2. Process Control

Resistance Welding

Projection Welding

Mig Welding Item Method Frequency

Inspection of part

Length, quantity and location of welds to be confirmed to approved �‘master�’ part

1 time per shift

Final Inspection

Must have final inspection on each part at the end of the process (burrs, cracks, missing, pin holes, excess splatter, off location, etc.)

100%

Master Part

Supplier must have a �‘master�’ part. Critical dimension data for each master must be available. Part to be current to design change level being produced.

All part numbers

Marker Check Inspections

Markers used must be approved by each applicable Honda plant to assure compatibility with Honda paint systems

100%




HSQM-0106 Page 3/4 03/12/09

Welding Minimum Process Requirements (continued) 3. Quality Confirmation

Resistance Welding

Projection Welding

Mig Welding

Inspection Item

Method Frequency

Quality checks (e.g. driver checks and torque checks)

Periodic quality checks to be done and results recorded. For parts utilizing 780Mpa and above materials, actual parts that are driver or torque checked are to be treated as nonconforming (i.e. tagged) and destroyed.

Beginning/middle/end of shift, abnormal conditions, and upon request

HES E 001-99 HES A 1018-

04 HES B 031-99

Honda Specification 5135Z-SX8-

T000

Quality Testing (e.g. macro testing)

Must be confirmed by applicable listed method. Results must be recorded.

1 complete test every 3 months (supplier must set-up a weekly rotation covering all welds during a 3 month period, including all jig/line combinations), abnormal conditions, and upon request

Quality Testing

Quality group must confirm length, quantity, and location of welds to Honda drawing

At New Model timing and as agreed upon with Honda thereafter


HSQM-0106 Page 4/4 03/12/09

Welding Minimum Process Requirements (continued) 3. Quality Confirmation (continued)

Resistance Welding

Projection Welding

Mig Welding

Inspection Item Method Frequency

HES E 001-99

and/or

HES A 1018-04

HES B 031-99

Honda Specification 5135Z-SX8-

T000

Non-Destructive

Testing (NDT)

The following requirements apply if NDT is to be used as an alternative to driver checking: *Supplier must achieve and maintain inspector certification per equipment maker guidelines. *Supplier shall have certified inspectors on site during all supplier production hours and shifts. *Supplier shall conduct NDT data correlation to destruct testing and driver check testing and review with Honda prior to implementing as a substitute to driver checks. *In the event of equipment downtime or certification lapse, supplier is required to follow the above driver check guidelines.

Negotiated between Plant and Supplier. NDT does not replace the minimum destruct requirements.

4. Abnormal Process Conditions

Resistance Welding

Projection Welding

Mig Welding

Inspection Item

Method Frequency

Driver/ Destruct Confirmations

Periodic quality checks to be done and results recorded. For parts utilizing 780Mpa and above materials, actual parts that are driver or torque checked are to be treated as nonconforming (i.e. tagged) and destroyed.

100%


Wire Harness Minimum Process Requirements

HSQM-0107 Page 1/5 03/12/09

Wire Harness Minimum Process Requirements Note: Must conform to drawing, specification, Honda Engineering Standard and any other applicable Honda issued or industry standards (e.g. IPC/WHMA-A620, JIS, etc.)



All components (clips, grommets, terminals, wire, waterproof seals, couplets, JC caps, etc.)

Must have documented procedure for receiving inspection. Results must be documented and filed.

Per supplier procedure

Spark test to be conducted per standard (Japan Ministry of Transportation unless otherwise directed by Honda). Results must be recorded, retained, and made available to Honda upon request (at supplier or sub-supplier).

1 time per month on each wire size

Wire Testing Voltage test to be conducted per related standard. Results must be recorded, retained, and made available to Honda upon request (at supplier or sub-supplier).

1 time per month on each wire size



Wire Harness Minimum Process Requirements (continued) 2. Cut and Crimp


SRS harness circuits denoted by Q point on drawing

Must have designated and automated cut and crimp equipment. Must have crimp force monitors and the circuit must be identified as critical throughout the production process.

100%

Circuits that, upon failure, can cause an ‘A’ or ‘G’ rank problem

(see the Supplier Quality Manual for explanations on rank)

Must have crimp force monitors and the circuit must be identified as critical throughout the production process

100%

All other circuits using automatic cut and crimp equipment Mis-strip sensors 100%

All circuits using manual cut and crimp equipment Visual inspection

200% ( two separate 100% checks)

Bell mouth, crimp heights, vinyl height, pull test, strip length, wire size, wire type, wire color, etc. Must be verified and documented.

One per lot

Set-up procedures Set-up wire samples must be different length than mass production lengths to be easily distinguishable

100%

Crimping Condition Visual inspection for damaged terminals, no strands out, no cut strands, no high/low insulation, etc.

100%

Terminal Protection All bundles must have protective covering over terminals during transportation and handling

100%

Twist Wire Machine set up for pitch control At start of each production run

Shield Wire Visual inspection for nicks and cuts due to stripping 100%

Splice Taping Taping must completely cover splice area. Must have visual inspection to confirm. 100%

Splice Location

Must be positioned in non-critical areas as identified by drawing. Prohibited joint locations to be identified on harness board layout (mass production and NM prototype boards)

100%

Weld Condition Weld width, weld height, and weld pull force as agreed upon by Honda

First and last piece per shift or changeover

HSQM-0107 Page 2/5 03/12/09



HSQM-0107 Page 3/5 03/12/09

Wire Harness Minimum Process Requirements (continued) 3. Sub-Assembly / Assembly


Wire Storage at Sub-assembly Area Racks to be free of sharp edges to ensure no damage to wires 100%

Terminal Condition Visual inspection for damaged terminals. Damaged or suspect terminals are to be immediately prevented from being used.

100%

Terminal Location Operation standard to be supplemented by visual aid(s) showing terminal location by wire color for each coupler cavity

100%

Terminal Insertion “Push, Click, Pull” test must be performed on each terminal insertion 100%

Process Layout Same colored wires that have similar lengths must be assembled at different assembly stations

100%

Taping

Tape wires by pulling back from couplers to ensure wires are even lengths and have no excess wire or loops at coupler (tape starting at coupler and moving away rather than starting away from coupler and moving toward it)

100%

Component Containers and Aprons Containers and aprons must be free of dirt and foreign objects 100%

Correct Components Must have method or procedure to verify proper components are being used

At start of each production lot or line side delivery of additional components

Directional component, protector, and grommet orientation/presence

Poke yoke to assure correct orientation/presence as per drawing 100%

Branch orientation and length Board layout and fixtures 100%

Line Change Over Assembly boards to be identified with part number and design level 100%

Terminal contact with floor Supplier must have method to prevent terminals from contacting plant floor (aprons, troughs, etc.)

100%

Taping Techniques Must have effective taping method which does not change branch length or orientation out of specification

100%

Board Maintenance Inspection of assembly boards to ensure fixtures are tight, not broken, etc.

All boards at start of each shift or line change over

Corrugated Tube Assembly Must use applicator to install tubing to ensure no insulation damage 100%

Grease Application Must use automated equipment to guarantee grease fill until the terminal rear end is completely covered

100%



HSQM-0107 Page 4/5 03/12/09

Wire Harness Minimum Process Requirements (continued) 4. Inspection Boards

Item Method Frequency Component Presence (clips, grommets, protectors, clamps, retainers, secondary locks, boots, etc.)

Detection system to assure presence (micro-switch, fixture, holder, etc.) 100%

Multi-circuit Harnesses

Must use circuit check to verify continuity, missing circuits, missing components, terminal back out, shorts, extra circuits, etc.

100%

Confirm joint connectors (JC) have continuity and no shorts after JC caps are installed

100%

Circuit programs to be confirmed and approved by supplier

At New Model timing and each design change or Manufacturing Instruction (MI)

Circuit Check Program

Must have backup program available for each check circuit

To be created at New Model timing and each design change or MI

Circuit Check Confirmation

Use master harness to confirm program of circuit board and detection system. Master harness must be confirmed, approved, and controlled by supplier.

At start of each production day, each change over, and after each abnormal situation

Harness Dimensions

Must use inspection board and master harness to verify harness dimensions. Inspection board to be made to nominal specifications. Master harnesses to be made to 50% or less of tolerance. Inspection boards and master harnesses must be confirmed, approved, and controlled by supplier.

Used to check 100% of production. New inspection boards or master harnesses created at New Model timing, design change or MI as applicable.

Inspection Identification Unless otherwise specified by Honda, parts must be identified that they have passed all inspection processes

100%

Confirmation Boards

All final inspection boards (circuit check boards, dimensional check boards, component check boards, etc.) must be identified and controlled with part number and design level

100%

Inspection Data

Inspection data submitted to Honda must use Honda specifications (not supplier internal specifications or drawings) when judging quality conformance of harness

100% of required data submissions (New Model, IPPAAR/IPP, problem analysis, etc.)



HSQM-0107 Page 5/5 03/12/09

Wire Harness Minimum Process Requirements (continued) 5. Part Identification


Harness Labeling

Harness identification as specified by Honda. Harness labels to be traceable to production date and component lot ranges. Must have method to verify match of harness label to container label (e.g. bar code scan). Labels must be taped as flat as possible.

100% of specified parts

Part Marking (when specified by Honda)

Part markings must be confirmed to part marking drawing. Harness bar codes that are used by Honda to confirm correct part usage must have part marking embedded and meet Bar Code standard as described in the Honda Supplier Quality Manual.

100% at New Model timing, design change or Manufacturing Instruction

6. Abnormal flows

Item Method Frequency SRS (i.e. Air Bag) Harness No repairs allowed 100%


minimum process requirements - · pdf filemethods honda requires in applicable manufacturing...

Documents