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PRODUCTION PART APPROVAL PROCESS (PPAP)

Supplier Name/Location/Supplier Code:


Bourns Electronics Ireland

Mahon Industrial Estate

Blackrock

Cork

Ireland

Supplier Part Number:


Customer part number

583 242 99
Part/Family Description:

FUELCARD
Submission Date:

23/11/2005

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 1/29
PRODUCTION PART APPROVAL PROCESS (PPAP)

CONTENTS
TS16949 CERTIFICATION

PART SUBMISSION WARRANT

DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART

CONTROL PLAN / MEASUREMENT SYSTEM STUDIES

PART DRAWING & DIMENSIONAL REPORT

RESISTANCE MEASUREMENT REPORT

MATERIAL CERTIFICATION & IMDS APPROVAL

APPEARANCE REPORT

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 2/29
PPAP DOCUMENT NO.:0009-P
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 3/29
PRODUCTION PART APPROVAL PROCESS (PPAP)

PART SUBMISSION WARRANT

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 4/29
Part Submission Warrant
Bourns Part Number 3714X-BFY-000 Customer Part Number 583 242 99

Safety and/or Yes No Engineering Drawing


Government Regulation Change Level C Dated 10/17/2005
Additional Engineering Changes NONE Dated N/A

Shown on Drawing Number Purchase Order No. 70014346

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

BOURNS ELECTRONICS Dimensional Materials/Function Appearance


Supplier Name

MAHON INDUSTRIAL ESTATE Customer Name/Division PRICOL


Street Address
BLACKROCK CORK
City State Zip

Note: Has this part been reported in IMDS (or equivalent)? Yes No

REASON FOR SUBMISSION


✔ Initial submission Change to Optional Construction or Material
Engineering Change's) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Last PSW > 1 year old
Other - please specify
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
✔ Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and complete supporting data submitted to customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requirements: YES NO (If "NO" - Explanation Required)

DECLARATION
I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable
Production Part Approval Process Manual 3rd Edition Requirements.

EXPLANATION/COMMENTS: QTY 100


QTY 100
Print Name Title Sample co ordinator Phone No. 00353 21 4515 381 Fax No. 00353 21 4515 292

Supplier Authorized Signature Date 10/11/2005


Supplier E-mail Address

FOR CUSTOMER USE ONLY (IF APPLICABLE)


Part Warrant Disposition: Approved Rejected

Customer Name Customer Signature Date

uantities until
PPAP functional
DOCUMENT approval or waiver is
NO.:0009-P
ECO No.:05-0168
om customer. BOURNS ELECTRONICS IRELAND 5/29
PRODUCTION PART APPROVAL PROCESS (PPAP)

DESIGN FMEA / PROCESS FMEA / PRODUCTION PROCESS FLOW CHART

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 6/29
PRODUCT PART APPROVAL PROCESS(PPAP)

Bourns Electronics (Irl) FMEA Number : DFM-C0002


FMEA Revision : Rev G
Failure Mode & Effects Analysis ECO No.: 05-0046
Item : Automotive Fuel Level Sensor Design FMEA Prepared By : S P O'Sullivan
Model :3710X-XXX, 3714X-XXX FMEA Date (Rev.) 21-Feb-05
Core Team : JL, MO'B, SPOS, PB, EO'R FMEA Date (Orig.) 01-Aug-96

D
O
C Potential e
Potential S c R Responsibility & S O D R
Design Functions Potential l Cause(s) / Current Design t Recommended Actions
Effect(s) of e c P Target e c e P
& Requirements Failure Mode a Mechanism(s) Controls e Actions Taken
Failure v u N Completion Date v c t N
s of Failure c
r
s t
Gauge PPAP sample
Resistor Too Low 7 M Incorrect Design 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too Low 7 M Low ohms/square 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too high 7 M Incorrect Design 4 1 28
Inaccuracy qualification
Gauge PPAP sample
Too high 7 M Low ohms/square 4 1 28
Inaccuracy qualification
PPAP sample
Gauge Material unsuitable
Resistor value Drift 6 M 5 qualification, customer 2 60
Inaccuracy for environment
tests
Design Rules, PPAP,
No gauge
Termination Open circuit 8 C Incorrect Design 5 Gerber View, Artwork 1 40
reading
Inspection
Incorrect material
No gauge PPAP sample
Open circuit 8 C selection, Premature 2 2 32
reading qualification
element wear
Include in the product Template
Positioning of probe
Probe mark on resistor Eratic template for all product John O'Connell updated,
8 C points on wiper travel 4 Not listed. 5 160 8 1 5 40
card. opencircuit that requires probing 16-1-05 design
area.
near the potential wiper procedure
Incorrect Circuit Incorrect PPAP sample
7 C Design Errors 7 1 49 12/01/2005
Layout Output qualification

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 7/29
PRODUCT PART APPROVAL PROCESS(PPAP)

D
O
C Potential e
Potential S c R Responsibility & S O D R
Design Functions Potential l Cause(s) / Current Design t Recommended Actions
Effect(s) of e c P Target e c e P
& Requirements Failure Mode a Mechanism(s) Controls e Actions Taken
Failure v u N Completion Date v c t N
s of Failure c
r
s t
Incorrect gap Design Rules, PPAP,
Termination Shorts circuit Erratic output 7 c 7 1 49
between tracks Artwork Inspection

Design Rules, PPAP,


Short circuit Erratic output 7 c Incorrect Design 3 2 42
Artwork Inspection

PPAP sample Reliability testing to be Completed,


Erratic gauge Material unsuitable
Resistor value drift 7 m 5 qualification, customer 2 70 carried out to verify Tom Burke 2003/4 Drift within 7 4 2 56
output for environment
tests material suitability specification.

Drawing checked by
Incompatible
Design Engineer,
Substrate Dimensions Parts not to size with customers 8 M Design Errors 5 1 40
PPAP Sample
assembly
Qualification

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 8/29
PRODUCT PART APPROVAL PROCESS(PPAP)
POTENTIAL FAILURE MODE FMEA Number : PFM-C0003
FMEA Revision : Rev M
AND EFFECTS ANALYSIS ECO No.: 05-0132
(PROCESS FMEA) Prepared By : S P O'Sullivan
FMEA Date (Rev.) 22-Jun-05
Item Automotive Fuelcard Process Responsibility Bourns Ireland Mfg Eng FMEA Date (Orig.) 27-May-99
Model 3714X-XXX-XXX Key Date : 22nd June 2005
Core Team M Delaney-Man, P Bradley - NPI,S.P.O'Sullivan - Qaulity,P Berry - Thickfilm Eng,EO'Regan - Prod Line Mgr
D
O
Process C Potential Current Current e
Potential S c R Responsibility & S O D R
Functions & Potential l Cause(s) / Process Process t Recommended Actions
Effect(s) of e c P Target e c e P
Requiremen Failure Mode a Mechanism(s) Controls Controls e Actions Taken
Failure v u N Completion Date v c t N
ts s of Failure Prevention Detection c
r
s t

Yield Certs of
Receiving Wrong material Supplier error/ No
impact/Line 7 2 Conformance / 3 42 N/A
Inspection (Inks) testing at Incoming
down Supplier evaluation

Material shelf life Yield Receiving


expired/nearing impact/Line 7 Supplier error 2 inspection/Operator 3 42 N/A
expiry down checks
Print definition
Poor print quality check. Bad
Slag too high 7 M Laser power settings 4 2 56 N/A
definition batches returned to
laser Scribe.
Scribe depth Breakage
Laser Scribe 7 M Laser settings 1 Checks,SPC 1 7 N/A
incorrect problems

Inconsistent Check size at setup


Scribe position 6 M Laser programming 2 1 12 N/A
element sizes at Laser Scribe

Increase scribe Variance for scribe


Shallow scribe
Clean break on Mis reg. On depth,make Go/No Go depth, to be ECO'd Pbe
Laser Scribe 7 M depth, worn breaker 4 Visual check 8 224 Complete 7 2 4 56
edge print. gauge PM on block, Blocks to be
block
and gauge implemented. MD

Print defect -
Open Circuit/ Install & Commission
Print Top Term Voids, Bridging, 8 M Print settings 3 Visual, X-Ray Visual 8 192 SPOS July 2005
Short Circuit Vision detection system
Blobs etc

Templates filed by ink


type, Segration of ink
Ink jar label, PO Mike D. July 16.
Print Top term Wrong Ink used. Reliability issue 8 M Wrong ink selected. 4 5 160 types. Cross referance Completed 8 2 4 64
stating ink type Sean P. July 16
of lot numbers to COC's
PPAP DOCUMENT NO.:0009-P in QA.
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 9/29
PRODUCT PART APPROVAL PROCESS(PPAP)
Templates filed by ink
type, Segration of ink
Ink thickness Ink thickness Mike D. July 16.
Print Top term Reliability issue 8 M Wrong setup 2 Dektak 2 32 types. Cross referance Completed 8 2 4 64
incorrect measuring machine Sean P. July 16
of lot numbers to COC's
in QA.

Print defect - Update design rules to JL; PB; EO'R;


Print Top Term Voids, Bridging, Open Circuit/ 8 M Design Problems 6 Design Rules 2 96 reflect actual print Customer. ECD Wk 26 Completed 8 4 2 64
Blobs etc Short Circuit capability 2001

Add checks to Procedures, Mesh PB,


Procedures /
Procedure. Change to ECD Wk 28;
Mesh
8 M Screen problems 7 Visual 8 448 280 Mesh for screens. Effectivness, PB, ECD 8 4 2 64
change
Verify effectiveness. Wk 28; Tester, SPO'S,
completed
Add shorts / open tester ECD Wk 25 2001

Open Circuit on Update procedures to


Procedure
Print alignment part of wiper 8 M Incorrect print setup 5 Visual 8 320 incorporate set up P.B. ECD Wk 13 2001 8 4 2 64
Updated
stroke alignment checks

Procedure PB, Wk 20,


2001 Data does not
Update procedure to
Dry & Fire top Open Circuit/ Parts piling up at support need for Procedure
Scratches of term 8 M 4 Visual & laser trim 5 160 scrap plates which pile 8 4 1 32
term Short Circuit end of dryer scraping plates, revised Updated
up.
proceedure. Week 25
2002

TR setup check.
TR values out
Resist Print Resist Voids 8 Mi Incorrect setup 3 Resistance check at 1 24 N/A
of spec
laser trim.

Visual & Elect Visual & electrical


Print misaligned 7 M Incorrect setup 3 2 42 N/A
failure check at laser trim

Surface
Wiper Stiction 7 Procedure 4 112
Treatment 1 Surface Treatment Pat Bradley
Missed Process Operator Error 4
Shortened process goes in-line. 31st Sept 2005
5 Routing 4 80
lifetime

Reduced track
5 Torque check 3 45
thickness

Operating
Debris on part 5 Incorrect setup 3 45
pressure too high
Smearing of Current check 3
5 45
ink
PPAP DOCUMENT NO.:0009-P
Broken plates 5 45
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 10/29
PRODUCT PART APPROVAL PROCESS(PPAP)

Wiper Stiction 7 Torque check 3 63


Operating
Incorrect setup 3
pressure too low
Shortened
5 Current check 3 45
lifetime

Wiper Stiction 7 56
Worn Active Active element
4 PEMAC 2
Element Shortened wearing with use
5 40
lifetime
Incorrect Active Multiple materials in Stock only 1
Contamination 5 4 3 60
Element stock material
Active Element
Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Damage
Contamination on Contaminated
5 No active cleaning 4 Air knife 3 60
tooling parts
Ink
Wrong plate
smearing/shorti 5 Operator error 3 Procedure/diagrams 3 45
orientation
ng
Surface
Wiper Stiction 7 Procedure 4 112
Treatment 2 Surface Treatment Pat Bradley
Missed Process Operator Error 4
Shortened process goes in-line. 31st Sept 2005
5 Routing 4 80
lifetime

Reduced track
5 Torque check 3 45
thickness

Operating
Debris on part 5 Incorrect setup 3 45
pressure too high
Smearing of Current check 3
5 45
ink
Broken plates 5 45

Wiper Stiction 7 Torque check 3 63


Operating
Incorrect setup 3
pressure too low
Shortened
5 Current check 3 45
lifetime

Wiper Stiction 7 56
Worn Active Active element
4 PEMAC 2
Element Shortened wearing with use
5 40
lifetime
Incorrect Active Multiple materials in Stock only 1
Contamination 5 4 3 60
Element stock material
Active Element
Wiper Stiction 7 Lack of inspection 3 PEMAC 2 42
Damage
Contamination on Contaminated
5 No active cleaning 4 Air knife 3 60
tooling parts
Ink
Wrong plate
smearing/shorti 5 Operator error 3 Procedure/diagrams 3 45
PPAP DOCUMENT
orientation NO.:0009-P
ng
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 11/29
PRODUCT PART APPROVAL PROCESS(PPAP)

Visual control & WK, LC, TH, ECD -


Customer
colour coded Week 25 2000
reject - can Mishandling & m/c Install 100% autotester
Laser trim Untrimmed parts 7 C 5 storage of 8 280 Eliminated requirement w 7 4 1 28
cause end user malfunction after laser Trim
trimmed/untrimmed for colour code
failure
parts racks.Week 15 2002

Customer
Dielectric Print, Poorly Covered reject - can Incorrect print set
3 Mi 3 Visual 8 72 n/A
and Cure resist cause end user up.
failure

Solder Stencil Poorly Covered Customer Incorrect Stencil set


3 Mi 3 Visual 8 72 N/A
print, and wash term pad reject. up

Customer
Poorly washed Incorrect Investigate potential for
reject, potential 7 Mi 5 Visual 8 280 Sean S.Week 05 Completed 1 4 7 28
part washing,check Corrosion
corrosion

Customer
Singulate into Op - visual QA - Install breaker in shorts TH, ECD - Week 25
Bad breaks cannot use 7 Mi Manual Breaking 5 8 280 Completed 7 2 5 70
units sample / open tester 2001
parts
At set up 1 L/T failure to
Machine Customer Incorrect set July 16 2003 Sean P.,
Shorts, Opens 7 C 3 Electrical test. 5 105 be taken, and tested to Completed 7 3 1 21
dynamic test Issues up.Machine fault Mike D.
verify failure
Final Process Customer Poor training /
No Inspection 7 C 3 Training/SDWT 2 42 n/A
Inspection issues Operator Error

Inspecting 1 PO at
Shipment
Packing Wrong labels 7 Operator error 2 a time. QA checks. 2 28 N/A
Return
Op checks

Inspecting 1 PO at
Customer dis-
Wrong Qtys 7 Operator Error 2 a time. QA checks. 2 28 N/A
satisfaction
Op checks

Inspecting 1 PO at
Customer dis-
Mixed parts 7 Operator Error 2 a time. QA checks. 2 28 N/A
satisfaction
Op checks

Final QA Defective parts Customer


7 Inspector error 2 QA Inspection 2 28 N/A
Inspection escaping complaints

Poor communication
More than 1 P/N Customer dis- at shipping/packing
Shipping 5 4 Shipping checks 3 60 N/A
per box satisfaction of customer
PPAP DOCUMENT NO.:0009-P requirement
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 12/29
PPAP DOCUMENT NO.:0009-P
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 13/29
PPAP DOCUMENT NO.:0009-P
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 14/29
PRODUCTION PART APPROVAL PROCESS (PPAP)

CONTROL PLAN / MEASUREMENT SYSTEM STUDIES

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 15/29
PRODUCT PART APPROVAL PROCESS (PPAP)

FUEL CARD PRE-LAUNCH CONTROL PLAN

P ROTOTYPE PRE-LAUNCH PRODUCTION KEY CONTACT DATE ORIGINAL DATE REVISION

CONTROL PLAN NUMBER MCP-0002 Sean P. O’ Sullivan 02.09.2003 26.05.2005


PART NUMBER LATEST REVISION CORE TEAM CUSTOMER ENGINEERING APPROVAL DATE IF REQD
37XXX-XXX-XXX REV. B (ECO #05-0111) SPOS , Pat Bradley, Sean Sugrue ,Peter Berry
PART NAME DESCRIPTION SUPPLIER/PLANT APPROVAL DATE CUSTOMER QUALITY APPROVAL DATE IF REQD
FUELCARD
SUPPLIER/PLANT SUPPLIER CODE OTHER APPROVAL DATE (IF REQD) OTHER APPROVAL DATE IF REQD
BOURNS ELECTRONICS IRELAND

Process Flow Machine, Characteristics Methods Reaction if out-of-control


Device,
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
Receiving N/A Ceramic Mfg As per Certificate of Appropriate part Micrometer, See Every Review C of C, Reject material, impound and
11 12 Inspection Process Conformance, Visual drawing as per Tool Scope, RP 003 ship- Material history, Identify with SCAR no.
& Dimensions BOM. Smart scope ment Usage in RTV as per OP-C6007.
production
Receiving N/A Conductor Mfg As per Certificate of C of C Review N/A Every File C of C Reject material, impound and
21 22 Inspection process Conformance Certificate of ship- Comply to Identify with SCAR no.
Conformance ment MM-C6015 RTV as per OP-C6007.
Receiving N/A Resist mfg As per Certificate of Review N/A Every File C of C Reject material, impound and
31 32 Inspection Process Conformance C of C Certificate of ship- Comply to Identify with SCAR no.
Conformance ment MM-C6015 RTV as per OP-C6007.
Screen Screen Bourns Screen Screen Blockage & Visual All All Check vs Reject Screen
51 52 Manufacture Stretcher & Manufacturing shorts. Screen TCPH3 Inspection. Screens Screens TCPH3
Exposure unit Tension. Tensiometer.
61 62 Receiving N/A Shipping tray N/A – Ship to stock Appropriate part N/A N/A Ship N/A Material rejected from floor
Inspection mfg process. drawing as per To On WIP.
BOM. stock Reject material, impound and
Identify with SCAR no.
RTV.

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 16/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

150 160 Laser-Scribe Camber guage Ceramic Mfg. Camber PS-C4000 Camber 5% of Every Log in L/S log Inform Mfg. Engineer for dispositio
Inspection Process Go / No Go ship- ship- book
guage ment ment
Do not process with order.
150 160 Laser Scribe C02 Laser scriber Laser scribing Scribe depth PS-C4000 Toolmakers 1 plate Every Log in MFG050
+ Scope 100 Green Zone = Normal production.
plates Pre-control White Zone = Continue but call
SPC Chart Technician
(MFG217) Red Zone = Stop and inform
Supervisor.
150 160 Laser Scribe C02 Laser scriber Laser scribing Scribe Position PS-C4000 Toolmakers See At setup Check Vs Re-check X+Y scribe m/c
& Product Scope PS-C And start Product template settings. If problem still exists
Template At set up + 4000 of every call technician.
start of every P.O.
P.O. Record
Record results results
+ On MFG 050 On
MFG 050
Break out Product template Vernier 30 6 Cpk >1.5. Manufacturing Engineer to
Dimension Calipers Pieces, Monthly. Calculate with Review and decide on
SPC Kiss. appropriate corrective action
Record results on if required.
Network server

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 17/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
250 260 Term Print Screen Printer Screen Printing Ink Thickness Limits as per layer Automated At setup Check results At set-up- Change squeegee,
Card SI-C-4193 Vision system And vs Layer Card, Screen, check pressure
1 plate Every log on QA1000 - as required.
+ or 100 In Process- Isolate product
plates and inform Supervisor &
Engineering
X-ray Disposition :
machine (a) Confirm product
outside specification.
(b) If outside specification
scrap affected units
in order.

Alignment & Product template Automated At setup Check results


Gap Width Vision system And Vs Product template
Or shadow 1 plate Every Log on QA1000
graph 100
plates

Product template Smartscope 30 Every Cpk >1.5. Manufacturing Engineer to


Pieces, 6 Calculate with Review and decide on
6 gap Months. SPC Kiss. appropriate corrective action
measur- Record results on if required.
ements, Network server
1 align-
ment
measu-
rement.
Impound P.O. and inform
Dektak Print Every Log Results on engineering for disposition.
270 280
Term
Drier & furnace
Drier & furnace
Thickness + PS-C4088 Thickness 1 plate 200 QA1000. Check vs
Dry & fire Settings / profile
Meter plates spec

As per As per Check against


290 300
Visual Mantis Inspection
Visual inspection Visual Defects + PS-C4088 Visual check PS- PS- PS-C4088, Units rejected.
Inspection Station
C4088 C4088 Log rejects on plate.

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 18/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method
450 460 Mix Inks Printer, drier, Ink Mixing OP-4033C Furnace room
& furnace & & & data-base / As Per As Per
qualify Furnace-room Ink qualification Resistance ME0032C Multimeter Ink Ink Check program Re-blend & Re-qualify inks.
Ink data-base / qual. qual. results vs TF
multimeter + require require database
ment ment

470 480 Resist Print Screen Printer Screen Printing Alignment Product Template Shadow graph 1 plate At set- Record results on Set-up = Reject if outside
+ up & QA1000. tolerance. Adjust printer and
every Check vs Template verify alignment within limits.
100 In Process = Isolate product
plates since last measurement,
screen for out of spec
product and scrap
Inform Supervisor and
Printing Operator.
Disposition :
(a) Supervisor to detemine
if Yield loss at Laser is
acceptable. If Not Scrap
entire order.
Log Results in (b) Inform Ink Qual Operator
Furnace-room Every Furnace-room and retarget ink prior to
Resist +
490 500 Drier & Furnace Resistance PS-C4088 database &/ 1 plate 100 database or on processing further
Dry & fire Drier & furnace
settings /profile Multimeter plates MFG194, if D-Base orders.
is not available.

Inform Supervisor. Stop


Surface Surface treatment Speed Offline Fuelcard Torque
600 610 Torque PS-C4232 1 plate Weekly Brushing process till
Treatment 1 machine Motor Current Calibration Fixture
corrected.

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 19/29
PRODUCT PART APPROVAL PROCESS (PPAP)
Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control
No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

Visually inspect laser cut to


At set-
5 determine cause of problem.
Laser Trim Trimming TR up and Check vs Laser
800 810 Laser Trim Resistance C PS-C4197 Multimeter trimmed Check all parts back to last
Machine Value every Trim Database
units check. Mark rejects with
30 mins
marker.

Cpk > Set-up = Reject if outside


1.66. Manufacturing tolerance. Adjust printer and
Review Engineer to verify alignment within limits.
6 Cpk review and decide on In Process = Isolate product
PS-C4197 Trim Database
Monthly results appropriate correctiv since last measurement,
In trim action screen for out of spec product
databas if required. and scrap
e.

At set- Determine cause of problem.


Laser Trim 5 up and Check all parts back to last
Microscope Visual Inspection check. Mark rejects with
Machine Finish quality Kerf cleanliness trimmed every
Laser Trim
and Position C PS-C4197 Vision System
units 30 mins marker.

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 20/29
PRODUCT PART APPROVAL PROCESS (PPAP)

Process Flow Machine, Device, Characteristics Methods Reaction if out-of-control


No. Process Jigs, Tools for Process Product Class Product/Process Measurement Sample Analysis Conditions are encountered
Process Check Name Manufacturing Parameters Characteristics Specification Method Size Freq. Method

Call a technician if coverage


Solder print Stencil printer & Solder paste Solder coverage + PS-C4219
815 816 Visual 100% 100% Visual Check or alignment are not correct
on pads Vitronics oven printing and alignment PS-C4218

Notify NPI Program Manager


820 830 Final Test TR Meter Final Test Resistance Value C Product Template TR Meter 50 units 100% TR Test. Foe Eng. Analysis.

Notify NPI Program Manager


Final Go / No Guage For Eng. Analysis
N/A Dimensional Dimensional Product Template 50 units 100% Guage
Inspection
900 910 Checks
Smartscope Notify NPI Program Manager
Customer Drawing 2 units 100% Record results
For Eng. Analysis

As per Visual Reject batch and re-screen


Final Visual defects Visual
N/A Visual Standards in 100% 100% Visual check
Inspection e.g. short-circuits Analysis
MM-C6804
As per Reject batch send for
Final Packaging &
N/A N/A MM-C6804 Visual MM- 100% Visual check Screening.
Inspection Documentation
C6804
As per Reject shipment, re-pack.
Packaging &
920 930 Shipping N/A N/A MM-C7026 Visual MM- 100% Visual check Inform supervisor.
Documentation
C7026

Special Characteristics Codes


(Class)
C Critical

+ Major (Significant)

_ Minor

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 21/29
Piece Part, Model, or Part Number: Division: Quarter & Year:

FUEL CARD Trimpot Q03 '05


Measurement Systems Analysis Statistical Process Control Process Capability SPC CONTROL
Critical Characteristic Type & Model GR&R Date of Last Chart Sample Sample DOE FOR LAST 3 MONTHS
and Specification of Gage % Mea. Study Type Size Frequency Cp Cpk Status
VISUAL AND DIMENSIONAL SMARTSCOPE 9.20% 29/06/2004 NONE NONE NONE n/a n/a n/a none none n/a
VERIFICARION
SCRIBE DEPTH RHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 2.31 2.08 N/A IN IN IN
0.010" +/-0.002 INCH SCOPE CHART 4 HRS
SCRIBE DEPTH LHS TOOLMAKERS 15.35% 10/02/2005 X/R 5 PIECES EVERY 1.76 1.64 N/A IN IN IN
0.010" +/-0.002 INCH SCOPE CHART 4 HRS
TERM WIDTH (wet) BEI VISION 13.00% 27/09/2005 NONE 1 PLATE EVERY 100 1.73 1.18 N/A none none n/a
.006'+/-.001 SYSTEM PLATES
TERM THICKNESS DEKTAK 21.50% 29/06/2004 NONE 1.84 1.12 N/A none none n/a

TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 1.50 1.44 N/A none none n/a
WIDTH (.016+/-.003 INCH) SYSTEM PLATES
TERM ALIGNMENT BEI VISION 5.50% 06/07/2005 NONE 1 PLATE EVERY 100 0.93 0.92 N/A none none n/a
LENGTH (.010"+/-.003 INCH) SYSTEM PLATES
RESISTANCE MULTIMETER 0.20% 05/07/2004 NONE 2.90 1.68 n/a none none n/a
kiln pre trim HP34401a
LASER TRIM MULTIMETER 8.60% 29/06/2004 NONE 3.13 2.74 N/A none none n/a
RESISTANCE KEITHLEY 2010
QA DIMENTIONAL VERNIER 15.95% 26/07/2005 NONE 2.09 1.62 N/A none none n/a
LENGTH(38.1mm +0.25 /-0.05) MITUTOYO 500-191
QA DIMENTIONAL VERNIER 17.72% 26/07/2005 NONE 2.37 1.33 N/A none none n/a
WIDTH (16.40mm +.25/-.05) MITUTOYO 500-191
QA DIMENTIONAL VERNIER 11.82% 29/06/2004 NONE 4.00 3.60 N/A none none n/a
THICKNESS (.63mm=/-.07mm) MITUTOYO 500-191
PRODUCTION PART APPROVAL PROCESS (PPAP)

PART DRAWING & DIMENSIONAL REPORT

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 23/29
21

20

19

18

17

16

11

2
10
15

14 9
8
13 7

12
5
6

3
PRODUCTION PART APPROVAL - DIMENSIONAL RESULTS
Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 B
Customer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM
Measurement Method : Smartscope
Unit 1 Unit 2 Unit 3 Unit 4 Unit 5

Item Nominal Tol + Tol - Units Min Max Special Actual OK Actual OK Actual OK Actual OK Actual OK

DIM1 35.9 0.10 -0.10 35.8958 35.9182 35.9179 3 35.9179 3 35.9182 3 35.9056 3 35.8958 3
DIM2 16 0.10 -0.10 15.9993 16.0097 16.0001 3 15.9998 3 15.9995 3 16.0097 3 15.9993 3
DIM3 0.635 0.05 -0.05 0.6100 0.6200 0.6200 3 0.6200 3 0.6200 3 0.6100 3 0.6100 3
DIM4 15.85 0.05 -0.05 15.8006 15.8618 15.8073 3 15.8096 3 15.8618 3 15.8006 3 15.8252 3
DIM5 4.45 0.10 -0.10 4.3796 4.4544 4.4544 3 4.3836 3 4.3796 3 4.4085 3 4.4057 3
DIM6 3 0.15 -0.15 2.9972 3.0282 2.9972 3 3.0048 3 3.0282 3 3.0044 3 3.0055 3
DIM7 5 0.15 -0.15 4.9931 5.0386 4.9931 3 5.0130 3 5.0386 3 5.0005 3 5.0311 3
DIM8 0.3 0.10 -0.10 0.8164 0.8216 0.8191 0.8174 0.8164 0.8216 0.8194
DIM9 14.5 0.20 -0.20 14.5069 14.5475 14.5475 3 14.5069 3 14.5220 3 14.5117 3 14.5309 3
DIM10 16.5 0.05 -0.05 16.5414 16.5472 16.5472 3 16.5436 3 16.5414 3 16.5447 3 16.5444 3
DIM11 18.5 0.25 -0.25 18.4795 18.5144 18.5144 3 18.4795 3 18.4934 3 18.4920 3 18.5043 3
DIM12 2.9 0.10 -0.10 2.8466 2.9076 2.8618 3 2.8581 3 2.9076 3 2.8466 3 2.8581 3
DIM13 5.85 0.15 -0.15 5.8601 5.9043 5.8601 3 5.8882 3 5.9043 3 5.8789 3 5.8887 3
DIM14 53.19 0.50 -0.50 53.5253 53.6889 53.6889 3 53.5253 3 53.6193 3 53.6134 3 53.5282 3
DIM15 56.19 0.50 -0.50 56.2135 56.3012 56.3012 3 56.2245 3 56.2135 3 56.2358 3 56.2272 3
DIM16 73.87 0.50 -0.50 73.8953 73.9500 73.9500 3 73.9241 3 73.8977 3 73.9106 3 73.8953 3
DIM17 89.02 0.50 -0.50 89.0379 89.0938 89.0749 3 89.0938 3 89.0621 3 89.0604 3 89.0379 3
DIM18 104.45 0.50 -0.50 104.4698 104.5508 104.5065 3 104.5508 3 104.4941 3 104.5221 3 104.4698 3
DIM19 109.9 0.50 -0.50 109.9144 109.9994 109.9399 3 109.9994 3 109.9605 3 109.9684 3 109.9144 3
DIM20 122.42 0.50 -0.50 122.4417 122.5419 122.4500 3 122.5419 3 122.4979 3 122.5010 3 122.4417 3
DIM21 126 0.50 -0.50 126.2407 126.4399 126.2786 3 126.4399 3 126.2407 3 126.3801 3 126.3533 3
PRODUCTION PART APPROVAL PROCESS (PPAP)

RESISTANCE MEASUREMENT REPORT

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 24/29
Supplier: BOURNS ELECTRONICS Bourns P/N : 583 242 99 B
Customer P/N : 3714X-BFY-000 Revision C Description : RESISTOR, THICK FILM
Measurement Method : Keithley Multimeter
RST.# R1 R2 R3 R4 R5 R6 R7 R8
NOM. TR. Ω 2.00 5.00 17.00 32.50 50.00 70.00 120.00 125.00
Tolerance + 0.50 0.50 0.50 0.50 0.50 0.70 1.20 1.25
Tolerance - -0.50 -0.50 -0.50 -0.50 -0.50 -0.70 -1.20 -1.25
1 1.9571 5.0455 16.958 32.466 49.961 69.935 120.03 125
2 1.9586 4.9708 16.975 32.454 49.964 69.911 120.03 125.03
3 1.9641 5.1183 16.969 32.454 49.98 69.916 120.04 125.07
4 1.9654 5.1171 16.964 32.464 49.981 69.98 120.1 125.07
5 1.9668 4.9605 16.968 32.469 49.979 69.901 120 125.01
6 2.0146 5.0553 16.989 32.493 50.032 69.955 120.07 125.05
7 1.9978 5.1506 16.991 32.497 50.008 69.97 120.07 125.06
8 1.9961 5.0464 17.011 32.502 50.018 69.969 120.13 125.07
9 1.996 5.0308 17 32.484 50.074 69.94 120.07 125.07
10 2.0174 5.0305 17.009 32.52 50.027 69.999 120.09 125.09
11 1.9954 5.1542 16.997 32.504 50.012 69.977 120.09 125.04
12 2.001 5.0454 16.994 32.503 50.015 69.949 120.08 125.06
13 1.9976 5.0098 17.002 32.493 50.013 70.031 120.06 125.01
14 1.9979 5.0602 17.001 32.514 50.021 69.942 120.08 125.09
15 1.9835 5.0899 16.987 32.511 50.003 69.994 120.08 125.11
16 2.0091 5.0402 17.003 32.502 49.99 69.955 120.14 125.12
17 1.9934 5.1129 17.009 32.5 50.012 69.949 120.1 125.1
18 1.9944 5.1028 17.001 32.499 50.012 69.947 120.09 125.09
19 2.0045 5.031 17.002 32.498 49.982 69.975 120.03 125.04
20 1.9859 5.0445 16.988 32.496 49.994 70 120.09 125.1
21 1.9793 4.9934 16.984 32.487 50.007 69.893 120.04 125.01
22 1.9756 5.0825 16.98 32.48 49.991 69.963 120.1 125.11
23 1.966 4.9686 16.984 32.489 49.977 69.965 120.04 125.03
24 1.961 5.0874 16.977 32.469 49.978 69.947 120.07 125.09
25 1.9652 4.9777 16.974 32.491 49.981 69.924 120.08 125.04
26 2.0004 5.1785 16.995 32.491 50.004 69.959 120.01 125.02
27 1.9807 5.0044 16.997 32.485 50.003 69.965 120.04 125.03
28 1.9805 5.1058 17.002 32.506 49.995 69.959 120.1 125.07
29 1.9871 5.0871 16.983 32.501 50.005 69.974 120.09 125.08
30 2.0017 5.0724 16.992 32.498 50.006 69.923 120.11 125.07
31 1.9915 4.9903 16.993 32.497 50.005 69.954 120.07 125.05
32 1.9876 5.1488 16.998 32.501 50.008 69.949 120.15 125.08
33 1.9712 4.9906 16.99 32.484 49.99 69.943 120.07 125.07
34 1.9749 4.9797 16.983 32.477 49.985 69.961 120.1 125.1
35 1.981 5.0072 16.986 32.484 49.985 69.935 120.13 125.07
36 1.9918 5.1638 16.983 32.492 50.019 69.94 120.1 125.07
37 1.9996 5.0066 16.992 32.501 50.005 69.993 120.06 125.07
38 1.9733 5.0317 17.004 32.501 50.021 70.005 120.13 125.09
39 1.9723 5.1322 16.985 32.47 50.022 69.943 120.09 125.06
40 1.9928 5.1354 16.999 32.481 49.998 69.941 120.05 125.03
41 2.2248 5.2413 17.203 32.689 50.208 70.169 120.3 125.29
42 2.2009 5.2474 17.193 32.693 50.204 70.156 120.24 125.22
43 2.1958 5.2742 17.193 32.705 50.213 70.122 120.27 125.29
44 2.2068 5.2529 17.202 32.709 50.23 70.153 120.34 125.31
45 2.2201 5.2914 17.223 32.718 50.215 70.257 120.29 125.28
46 1.9753 5.0116 16.986 32.488 49.997 69.887 120.07 125.02
47 1.9717 5.0925 16.971 32.5 49.986 69.962 120.09 125.06
48 1.982 5.0394 16.987 32.481 49.988 70.116 120.04 125.02
49 1.9775 5.021 16.968 32.484 49.98 69.939 120.05 125.03
50 1.9794 5.1157 16.991 32.476 50.018 69.957 120.11 125.06

MEAN 2.01 5.08 17.01 32.51 50.02 69.98 120.10 125.08


Std. Dev. 0.07 0.08 0.07 0.07 0.07 0.08 0.07 0.07

Max. 2.22 5.29 17.22 32.72 50.23 70.26 120.34 125.31


Min. 1.96 4.96 16.96 32.45 49.96 69.89 120.00 125.00

Cm 2.39 2.00 2.52 2.52 2.47 3.09 5.53 5.72


Cmk 2.36 1.68 2.47 2.46 2.36 3.00 5.08 5.35

NAME: Caroline Hickey DATE: 10/11/2005


PRODUCTION PART APPROVAL PROCESS (PPAP)

MATERIAL CERTIFICATION & IMDS APPROVAL

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 25/29
3714X-BFY-000 583 242 99

PRICOL

50053028 10/11/2005

CERAMTEC 05/0664 05/09/2005


TANAKA 4865 1367 27/10/2005
DUPONT RESIST QS 871 PFP296 20/9/2005
DUPONT RESIST QS 872 PFP243 11/10/2005

CAROLINE HICKEY
23/11/2005
PPAP DOCUMENT NO.:0009-P
ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 26/29
PRODUCTION PART APPROVAL PROCESS (PPAP)

APPEARANCE APPROVAL REPORT & PACKAGING DESCRIPTION

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 28/29
Fuelcard Appearance Approval Report
PART NO. DRAWING NO.
3714X-BFY-000 583 242 99
SUPPLIER NAME MANUFACTURING LOCATION SUPPLIER CODE
BOURNS ELECTRONICS IRL DSZ QA

DEFECT DESCRIPTION PASS FAIL COMMENT

VOIDS ✔
PROTRUSIONS ✔
SOLDER COVERAGE ✔
BLISTERS ✔
SCRATCHES ✔
MARKINGS ✔
JAGGED EDGES ✔
OPEN CIRCUITS ✔
SHORTS ✔
CONTAMINATION ✔
SMEARS/SMUDGES ✔
OTHER

INSPECTED BY TELEPHONE NO. CUSTOMER USE ONLY

CUSTOMER REPRESENTATIVE SIGNATURE DATE


CAROLINE HICKEY ✔
00353 21 4515 381
MARK MARTIN

PPAP DOCUMENT NO.:0009-P


ECO No.:05-0168 BOURNS ELECTRONICS IRELAND 29/29