Product Characteristics Classification

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KSS Global StandardProduct Characteristic Classification

Doc. No: 1033079 Rev. 3 Page 1 of 9 Uncontrolled copy printed: 06-Dec-2012(KSS template no. 1033844 Rev. 2)

KSS GLOBAL STANDARD

Product Characteristics Classification(CC/SC Standard)

KSS 050

Document No: 1033079

Authors:Günther Hilbich

Approved by: Andreas Staub

Approved by: Dieter Hahn

Document History

Revision: Release Date ECP No. Modification

3Changed wording from Guideline to StandardRemoved Scarpa and Jost as Approvers

2 2 Mar 2012 509825.1- Note deleted; 5.2: Owners of CC/SC list columnscorrected; 5.4.2: D- FMEA added; 7: Attachment 2 added;

1 22 Sep 2011 47830 Fully revised standard


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Table of Content

INTRODUCTION ................................................................................................................................................. 3

1 PURPOSE................................................................................................................................................... 3

2 SCOPE........................................................................................................................................................ 3

3

RESPONSIBILITY ...................................................................................................................................... 3

4 DEFINITIONS / ABBREVIATIONS ............................................................................................................ 3

5 DETERMINATION OF SPECIAL CHARACTERISTICS ............................................................................ 4

6 REFERENCES (RELATED DOCUMENTS) ............................................................................................... 9

7

APPENDICES ............................................................................................................................................. 9


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Introduction

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

1 Purpose

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

2 Scope

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

3 Responsibility

The Engineering Manager or Director of each KSS engineering department isresponsible to ensure that the CC/SC standard is followed, monitored andobserved during development.

The Product Engineer is responsible to define the CC/SC for all engineeringdocumentation associated with development for the assigned programs.

The Quality Manager/ Director is responsible to ensure that requirements defined inthis standard are implemented.

The Procurement Director and Director of Supplier Quality are responsible tocommunicate this standard and enforce compliance at the supplier level.

4 Definitions / Abbreviations

A characteristic is a dimension or a physical, chemical, electrical, mechanical orvisual property. A characteristic must be measurable, either directly or indirectly,either variable or attribute.

Attribute characteristics are qualitative data that is measured or checked andresults in conformance or non-conformance, pass or fail.


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Variable characteristics are quantitative data which can be measured, and theresult is an absolute measurement reading eg. Millimeters, Inches, Newtons, etc.

There are two different types of special characteristics:

Critical Characteristics (CC)are product characteristics that may affect the

• safety of product or operator

• compliance with legal requirements

• environmental requirements.These characteristics are designated in the D- or PFMEA, having a causalrelationship to the effect of potential failure modes rated 9-10 for severity.

Significant Characteristics (SC)are product characteristics that may affect

• form, fit or function of the product

• the production (assembly) processThese characteristics are designated in the D- or PFMEA having a causalrelationship to the effect of potential failure modes rated 5-8 for severity, or whereagreed by the cross-functional team, having severity rated less than 5.SC characteristics may be influenced by the manufacturing process (KSS and/orsuppliers) and may require special control to maintain the required processcapability and customer requirements.

5 Determination of Special Characteristics

5.1 Identification

Source of specialcharacteristics

Criteria Outcome

DFMEA Severity rating = 9, 10 CC

DFMEA Severity Rating = 5 – 8Occurrence= 4-10

SC

PFMEA Severity rating = 9, 10 CC

PFMEA Severity Rating = 5 – 8Occurrence = 4 – 10

SC

Customer or internalrequirements

CC or SC

Legal, environmentalrequirements

CC


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5.2 CC/SC List

Each DFMEA/PFMEA requires a CC/SC list as a controlled document (seeappendix) and is to be understood as a subset of the DFMEA.

The purpose of the CC/SC list is to monitor and assure that all specialcharacteristics are effectively controlled and documented during development andongoing production. It is a mandatory document and shall be used for each product.

Task Responsible

Owner of the CC/SC List *) Product EngineerList all CC/SC (column A- I) Product EngineerInput of data (column J-M )KSS Process Process EngineerInput of Data (components level) (column N-R) SQE

Input of data (module level) ( column N- R) SQA, (SQE)

*): In case of not timely deliverable of data, immediate escalation to ProgramManager (PM) is indicated. PM to escalate latest in TG review.

5.3 Control of CC/SC

5.3.1 During Development

All special characteristics determined as CC/SC during FMEA process shallbe carried forward to the CC/SC list, the drawings, the control plans, and tostandard work instructions.

All CC/SC shall be verified and validated during Design Validation (DV).

The supplier shall evaluate and implement the measurement methodapproved by KSS and other appropriate controls on characteristics related totheir processes.The supplier shall evaluate their processes and further identify, document,and control additional contributing characteristics.

All CC/SC shall be verified prior to any DV or customer builds.

5.3.2 During PPAP and Product Validation (PV)

All CC/SC on the drawings, control plans and other documents shall bereferenced in the PPAP documentation and proven capable.

Process capability must be proven for each special characteristic

• If capability cannot be demonstrated, 100% check must be performedwith proven detection of non-compliance

• If this is not possible other methods must be applied (e.g Poka-yoke)

• Compliance of attribute characteristics can be proven by using acertificate.


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The initial process capability study is to evaluate:

• The conformity of characteristics to the specified requirement and the

• effect of tool/process variation on these characteristics.

If material is identified as a CC a material certificate must be included inPPAP submission and must be available for each batch/lot during massproduction.

Capability studies shall be performed according to the AIAG manualStatistical Process Control (SPC), and measurement equipment shall beproven acceptable according to the AIAG manual Measurement SystemsAnalysis (MSA)/ ISO/TS 16949, latest editions.

Suppliers shall demonstrate their ability to perform capable measurement ofspecial characteristics according to methods agreed by KSS.

Evidence shall be provided during supplier APQP process.

5.3.3 During Serial Production

All CC/SC on the drawings, D- and PFMEA, and/or specifications shall beverified during serial production and reflected in approved control plans.

5.4 CC/SC List Management

5.4.1 All CC/SC lists shall be written in English. Dual language (local language andEnglish) can be applied as applicable.

5.4.2 Distribution of the complete CC/SC list data outside of KSS (customer or supplier)is prohibited, as well as D- and PFMEA, but can be presented upon request. Thesupplier shall be provided with the CC/SC list for his component.

5.5 Documentation of Special Characteristics

• CC/SC’s must be marked on the drawing according to the global KSS drafting

standard.• General numbering of characteristics (dimensions)

or


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• Table on the drawing specifying the identification number of the characteristics

• Some more examples

5.6 Documentation/Record retention

All documents referring to special characteristics shall be written in English or indual language (local language and english)

Record Retention is mandatory for each document and/or report referring tospecial characteristics.


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5.7 Summary and FAQ

CC SC

1 When to apply a CC/ SC Affects product andoperator safety and/orcompliance withregulatory requirements.

Affects product form, fitor function (other thansafety and regulatory) orhas other valid reasonsto classify significant

2 Is a deviation approvalpossible in case out ofspec.?

No Yes, temporarily

3 For new design and newtool after 31 Oct 2011

3.1 Evidence for PPAP

approval

Initial capability Ppk>2.0

orPoka-Yoke

or100% detection

If the CC applies tomaterial, a materialcertificate is required

Init. capability Ppk >1.67

orPoka-Yoke

or100% detection

(material spec. applies toCC classification)

3.2 Evidence in serialproduction

Continuous capabilityCpk >1.67, if verificationindicated by SPC(Statistical ProcessControl)

orPoka-Yoke

or100% detection

If the CC applies tomaterial, a materialcertificate is required onrequest.


orPoka-Yoke

or100% detection

(material spec applies toCC classification)

4 Existing design or toolsbefore 31 Oct. 2011

4.1 Evidence for PPAPapproval

Initial capability Ppk>1,67or

Poka-Yokeor

100% detectionIf the CC applies tomaterial, a materialcertificate is required

Init. capability Ppk >1.33or

Poka-Yokeor

100% detection(material spec. applies toCC classification)


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4.2 Evidence in serialproduction


orPoka-Yoke

or100% detection

If the CC applies tomaterial, a materialcertificate is required onrequest.


orPoka-Yoke

or100% detection

(material specapplies to CCclassification)

6 References (Related Documents)

- KSS Quality First Manual- KSS Global Drafting Standard

7 Appendices

1: CC/SC list template (Doc. No:1033080)2: List of CC/SC Symbols (Doc. No:1011538)