Devices and methods for the
dimensional control
Lastenheft
Metrology purchasing parts
Elaborated: René Lopez Pimentel
Metrology purchasing parts
VoBo.: Martin Hdez. Rivas
Measuring techniques
Revision: 8 (Oct. 2009)
Date of Origin: 21/Feb. /2000
Ing. René López Pimentel 19/05/10
Lastenheft_dispositivos (Eng) Hoja: 1 De: 29
Content:
I). - Plan of work ............................................................................................. p. 3
II). - Concepts of Messpunkte .......................................................................... p. 3
III). - Programs of measurement and report ................................................... p. 3
IV). - Method of liberation of pieces and process ............................................. p. 5
V). - Means concepts of dimensional control ................................................... p. 6
VI). - Characteristic for control systems and their liberation.
A): Characteristics for control of pieces in general ........................................ p. 6
B): Special characteristics.
B.I: Flexible plastic pieces ...................................................................... p. 11
B.II: Joints ............................................................................................... p. 12
B.III: Crystals ........................................................................................ . p. 12
B.IV: Carpets and similars ...................................................................... p. 12
B.V: Rigid pipes ...................................................................................... p. 12
B.VI: Flexible pipes ................................................................................. p. .13
VIII). - Annexed ................................................................................................ p. 14
VII). - References .............................................................................................. p. 26
For any doubt in the interpretation of this Lastenheft to go to following telephones 52+ (222) +2 30 99
51/2 30 94 91.
[email protected] // [email protected]
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I. – Wok Plan
For each product new and/or change of engineering, Supplier will have to present/display a
plan of terms to Metrology purchasing parts being indicated the times of the following
information:
1. - Delivery of concepts of Control fixture
2. - Delivery of concepts of Messpunkte
3. - Delivery of concepts of processes control graphics and its frequency
4. - Elaboration of measurement programs
5. - liberation of devices (with fixturemaker, contact and address)
6. - liberation of the product (with toolmaker, contact and address)
II. - Concepts of Messpunkte
The Supplier will have to present/display its proposal of messpunkte (measurement points)
and Funktionmasse (measured of function) to the specialist of Metrology purchasing parts,
taking like reference the drawing of the product and its components, model CAD, Norms,
etc.
The specialist of Metrology VWM, will give to his observations for the adjustment of the
points and characteristics, as well as their liberation for the elaboration of programs of
measurement of the Supplier.
The supplier will have to integrate in its proposal the zones of function like: position of
points of fixation, elements of control, surface union by weld, surface of comfort gaps and
flushes, faying surface with Vista pieces, cuts, etc. as well as the tolerances to apply and
the levels of engineering that work then (for assembles where the tolerance doesn’t
indicated, it have to take from draw of single parts or in funktionsmassekatalog if it exist).
One will be due to present/display graphically and co-coordinated nominal to assure that
one includes the area and correct distribution (to see annexed 10)
The distribution of points on surface and cut will depend on the form and size of the piece,
the guide for pieces of laminates and nonmetallic it is in annexed 11.
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III. - Programs of measurement and report
The measurement programs will have to be automated to reduce the times of measurement
to the maximum, will have to be generated with images where it sees the zones with
deviations, will be due unquestionably to report the geometric characteristics of diameters,
tolerances, levels of function, coordinates XYZ, vectorial deviation, etc. And in the
indicated standard format, also the levels of tm, tz, äkos added, date of production,
generation (01H, 01K, 01S, etc.)
When VWM require parts for different events (Meisterbock, Cubing, VFF, PVS, Serie 0,
SOP, etc.), The Supplier have to give the measuring report 100%, also the control graphic
to the asker and the specialist of Metrology purchasing parts without exception, and
specificity for the Meisterbock and Cubing event one part with the vectorial deviations
written as follow: In color green deviations for contours and/or cuts, and in color blue
deviations for surfaces (to see annexed 13)
There will be two forced programs:
The length program; that it contemplated to the evaluation to 100% the characteristics
decided and defined in the Messpunkte and this will be for the evaluation of liberation of
the product in the different events.
The short program; that it contemplated the strategically important points decided for the
control graphs, which will be for the resume status in the events, release of the process and
monitored of Series, the format will be as it is indicated in annexed No.12 including the
Cp, Cpk and the deviations in Ak, Bk, etc; definitions.
In case of special analyses by faults detected in line of production, audit, field, etc., will be
due to generate a third program, or those that are necessary to cover this necessity, but both
programs (long and short) will be irremovable, unless of the VoBo on the part of
Metrology purchasing parts.
The report, will have to fulfill the mentioned characteristics, including the leaf of
alignment, protocol of measurement and title page (to see annexed 1, 2, 3, 4 and 5).
The report for control graph will have to contemplate the Cp and Cpk (to see annexed 12 ).
For the case of plastic pieces, where the state of delivery to VWM is in ROH, one will be
due to correlate measures of experience between end item data CAD and ROH, that they
allow to make this monitored of process without depending on horned that simulates the
contractions undergone by the painting process.
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In case that the software of the Machine of measurement does not contemplate models
CAD, statistical package, etc. One will be due to cover the requirements mentioned
through leaves Excel with macros, bonds, etc., (to see annexed 6).
In some characteristics the drawings indicate clearly the average ones for the dimensional
evaluation, from the auxiliary material (ejem. shaft, diameter spheres specify, etc.) Until
the mark of the equipment to use. The Supplier in case of not having on this equipment
must indicate as it is the alternative to use to obtain he himself result and with the required
trustworthiness. It will have to indicate the alternative equipment to use, the method of
measurement clearly detailed and to validate it with an Inter study comparisons (to see
annexed 9)
The alignment leaf will have to indicate the taken RPS, Datum elements, References ROH,
etc., according to which it marks the drawing (The theory deviations on the RPS in the
axes that they have control is zero, where the alignment is with one point as in RPS of
surface, the tolerance to apply in his area will be according with the equation indicated in
the point A.12).
IV. - Method of liberation of pieces.
Previous to the liberation of Metrology VWM, Supplier it will have to send dimensional
report to the 100% (according to the Messpunkte defined) to demonstrate that they already
are in conditions of liberation. This measurement will have already to be with the definitive
program of measurement in the Machine of measurement by coordinates.
The monitored began from the phase of prototypes, gives for events of Meisterbock and
Cubing, VFF, PVS, Series Zero and SOP. For each event a dimensional report to the 100%
of at least 3 pieces will be due to give. In case of having deviations outside tolerance in
zones of function, the plan of correction with activities will be due to annex and times, this
plan must cover the delivery with pieces corrected before the following event (see format
in annexed 14).
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For the dimensional release of tool buy off, will be according as follow:
Supplier have to report at least 5 parts 100% according with the messpunkte, also the
control graphic defined, in both information Metrology purchasing parts have to give a
green status to release the tool buy off (every zones defined as Ok)
For the phases of liberation in PVS, Series zero and SOP will be come from the following
way:
In PVS: They will be due to evaluate of 5 to 10 pieces on control fixture, from those same
pieces were taken from 3 to 5 to be evaluated in machine of measurement by coordinates
(to confirm repeatability and validation of the method), with base to the results, conditions
and manufacture means the dimensional Note will be assigned.
In phase of Series zero and SOP: The product will have to be with means and in the
definitive place of manufacture. The same described mechanics will be followed for event
PVS and in addition they were evaluated of 20 to 30 pieces (single the points that marks
the graph of decided control) to as much release with base to the Cpk the product and the
process with definitive the dimensional Note.
In plastic pieces of great volume in ROH, the liberation of the CPM contemplated the
measurement of the piece against data CAD of the end item , for it will be due to evaluate
the piece putting under it horned that it simulates the conditions of the painting process.
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The Supplier of the final state of delivery, is the person in charge of the Quality of the end
item, as well as to assure the quality, during the project devolvement, monitored of series
and remedial actions of the products that receive from the sub-suppliers , even though these
are directed by VWM, that’s why the supplier have to prevent resources for the following
since their toolmakers.
For the case of products like modules of joint, Supplier this forced to control them
dimensionally as much for the liberation as for the monitored of series, deciding with
Metrology the strategically important points of measurement and means to use; even
though there is no drawing, in this case it was taken as it bases the drawings of the
components and the tolerances were validated with the area of documented DT VW and
with Purchases VW from the commercial negotiation.
V. - means Concepts of dimensional control and their liberation
In general the supplier has to consider with purchasing department the control fixture
and/or Cubing for the assesment of the product as variables
The supplier will have to give to its concept of control system to Metrology purchasing
parts, which must contemplate the characteristics indicated in the point IV.
The specialist of Metrology VW, reviewed the proposal, will give his commentaries and/or
VoBo to begin the manufacture of means, in opposite case they will be due to make the
corrections and to present/display the proposal again (concept examples Annexed 7).
The specialist of Metrology purchasing parts will use the check list, to evaluate the concept
of the device and for the liberation a made time (to see annexed 8)
The specialist of Metrology purchasing parts will defined if is necessary review the design
to assure the critical details in the product control.
In case that the manufacture of the device this a time for the measurement of the pieces and
is not required for it, the Supplier will have to have on auxiliary equipment that the device
can similar and thus to be able to make the dimensional evaluations for the different events
of the project.
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VI. - Characteristic for Control fixture and their liberation.
A): Characteristics for the construction and control of pieces in general.
A.1. - It must be constructed with rigid materials(1) and light(2), that supports the robust use
of line of production and in addition it facilitates its transfer. The dimensions must be such
that allow their positioning in a machine of measurement of standard size(3)
(1): It does not have to undergo flexions by handling or subjection.
(2): Can be transported by two people maximum.
(3): ~1500mm x 1500mm x 2500mm
A.2. - Parallel is due to construct to the axes of the car (assembly position), in exceptions
where another position is required (as long as by gravity, the weight of the piece does not
cause dimensional deviations that are not representative of the function in the car), it is due
to indicate clearly in the device (informative plate) the angles and references of turn.
A.3. - For inner and outer pieces (of Vista), the device of such form is due to construct that
allows to evaluate all the zones of Vista (Guaranteeing the evaluation of zones you criticize
of comfort and is even).
For assembly pieces (no Vista), it is not required of special configuration for the
control of the piece (Assuring the access to the measurement characteristics you criticize
and/or function).
A.4. - It must count on the references (noticeable) of alignment and origin X, and, Z (face
machinated [recommendable in low relief to avoid damages by robust use], hole, spheres,
to per to us).
A.5. - The piece and/or single joint must seat in RPS of surface (Fx, and, z), and single in
the area that indicates the product drawing (hachured). As thus also single it must locate
solely in RPS of hole (Hx, and, z)(3).
(3): Exceptions are indicated in points B.I.
A.6. - When using clamps, the zone of contact with the piece must be of rubber and it is
recommended that the separation between the plane of the rubber and the surface of the
device is 75% of the thickness of the piece (to see fig. 1). The center of the rubber must agree
with the center of support RPS
A.7. - The device must count on ears GO-NOGO for surface and cuts, pins localizers, gage
for size of hole, plate of fixation sequence and inspection, plates of references X, and, Z.
Etc.
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A.8. - They will be due to consider equipment of auxiliary measurement in the devices like
title page indicators, digitals, ultrasound, radio waves, etc.; that they have the capacity of
data collection, for the dimensional evaluation of forms and cuts directly in the device and
these values must be exported to a system of compute, a system DATAMATE is
recommended (to see fig. 2). The accuracy of them, have to be <=5% of the tolerance range.
The device must have the ability to generate a control by variables and thus to
determine and to generate a report of the Cp and Cpk.
75% of
thickne
Figure 1 Figure 2
A.9. - It must count on groups to evaluate the central forms of function (previously decided
with Metrology parts purchase VWM) (to see fig. 3).
A.10. - The device must count on Gaps(4) for control of forms (to see fig. 4):
In pieces whose tolerance is until ±0.8mm it requires a Gap of 3.0mm.
In pieces with tolerance of ±1.0 to ±3.0mm a Gap of 5.0mm is required.
In pieces with greater tolerances to ±3.0mm or with tolerance of surrounding (pipes)
it is not required of Gaps of comparison.
Gap used will have to be identified in the device.
(4): Exception points B.IV; B.V; B.VI.
Plantilla Apoyo
RPS
Gap
Gap
Dispositivo
Figura 3 Figure 4
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A.11. - One will be due to send to Metrology purchasing parts VWM, the concept of
construction of the device (with sketch), for his revision and approval (indicating average
of control: Type of localizers, gaps, pins, etc.).
The design of the device (dimensions, calculation of maximum and minimum tolerances,
etc.), is responsibility of the supplier and his tool maker; the liberation of the device will
become on the basis of the points A.12, A.13 and A.14), using the check list (official
formats) where the assessment is with measuring results, function, GRR results, accuracy
of SPC and correlation with the CMM (with a difference no more than 20%)
A.12. - It will be applied as tolerance to the dimensional deviations of control fixture with
base to the tolerance of the piece, using the statistical tool that determines the level
trustworthiness for the trazability of results:
±Tolerance of the device = (Rank of tolerance)/6 k
Where k=2(5) standard in the industry
(5): K=3 for points B.I will be applied; B.IV; B.VI.
A.13. - The device must be certified dimensionally to the 100% (surfaces, cuts, holes,
shafts, gages etc.), by the supplier/constructor or an external measuring room. Metrology
purchasing parts VWM, guaranteed this certification taking a sample from points measured
for the liberation of the same one; fulfilling the concept before already released and its
functionality. The supplier will have to also give the liberation through studies R&R
according to manual MSA (measurement systems analysis) and in the official format, where for
it will done for each SPC port, minimum 5 parts, 2 appraisers, 2 measurements (5x2x2) for
the pre-release from the supplier, and (10x3x3)for the official release in the place and
appraisers final.
A.14. - One will be due to guarantee that the results that throw the control fixture , have
repeatability with the measurements in Machine of measurement by coordinates and/or the
Cubing´s of VWM, (Simulator of the machinated aluminum car); Thus like controlling the
characteristics strictly of Lehrefunktionplan (map of dimensions of control), previously defined
in VWM. If the device is used like Messaufnahme (Average of fixation for measurement), it
must have the possibility of evaluating all the zones you criticize and of function, as much
in line of production as with machine by coordinates allowing the access of the feelers,
laser, white light, etc.
A.15. - When the device is a Cubing, it will have to strictly fulfill the characteristics of the
mentioned points A8 and A14.
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A.16. - One will be due to define between Metrology purchasing parts VWM and Supplier,
the criterion to consider if the piece is the sufficiently rigid or flexible thing.
A.17. - For pieces rigid, they will not be due to deform at the moment for applying clamps,
that is to say, is not due to hide sprig-back of the piece, clamps single must serve to hold
the piece, does not stop to physically force it.
A.18. - For pieces flexible, it will be allowed to physically force the piece with clamps.
But it will have to measure the Spring-Back maximum allowed before applying clamps.
The standard value for VWM is maximum 1.0mm to be considered like acceptable
SpringBack. The exception to this value will be due to determine with a functionality study
and to count with VoBo of Metrology the parts of purchase VWM.
A.19. - For the location of hole RPS, they will have to be used to per type localizers pins
(or retractable whose wharf does not have excessive determination, not to deform the
single piece and it could be applied where the RPS controls as much hole as establishment
surface, as well as to allow a look to drown the bolt for aims of special analyses). Single
will be accepted round if the RPS controls two axes, for which controls a single axis will
be due to have diamond localizers; all of them with completion in cone to assure the trim
the hole (to see fig. 5).
Figura 5
A.20. - The fixation of the piece through screws and/or nuts will not avoid, because this
system slows down the time of analysis and in addition the force to tightens throws results
different against a Machine from measurement and its behavior in the Car, that is to say, it
does not fulfill the A14 point, In case that it is device is required to simulate the fixation as
is in the traverse Car of these elements, will have to be an alternating system in he himself
device, to traverse of inserted and/or movable elements, and in addition torque will not be
due to apply of it tightens since the physical-mechanical conditions of the body in the Car
are flexible, whereas in the device they are rigid, It recommend a clipsado system of (see
fig. a, pag.13).
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A.21. - For the control of hole, VWM and supplier will be due to define between the
necessary ones to control with pins no excellent localizers and with forms painted in the
device.
Corte
Nominal
Corte
nominal
Tolerancia
Tolerancia
superior
superior
Tolerancia
Inferior
Figura 6 a
Gage para verificar corte
con tolerancia superior e
inferior
A.22. - The form of control of cut of silhouette in the pieces must be in the device in song
form, is not recommendable to control with painted lines (to see fig. 6a); If by construction
of the device a greater angle to 10° in the inclination of the piece is had, it will be due to
control with the song in perpendicular form to the cut of the piece (to see fig. 6b).
> 10° < 10°
Angulo normal
al corte de la
pieza
Figura 6 b
A.23. - The pieces must easily be mountable and tire irons to the device assuring the
absence collisions, damages or destruction of the piece.
A.24.- The frequency to inspect the control fixture and GRR validation in Serie, using the
check list, it will accord the use conditions, for that the follow equation will be applied.
N = K*O*A*H …………………………where:
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Parámetro Factor Comentario / Ejemplos
Cate goría de emple o K Sensibilidad, robustez del MP
baja 1 versión robusta, comp. estable en cuanto al tiempo
versión normal, casi sin comportamiento
mediana 2
de variación del cero
alta 3 versión sensible, comp. de variación del cero
Calificación del personal, condiciones del
Lugar de empleo O
entorno / del amacenaje
Sala de medición 1 Condiciones de laboratorio
Puesto de medición 2 desacoplado de la línea, a un lado de la producción
Producción 3 integrado a la línea, dependiente del ciclo
Clase de empleo A Uso, desgaste, empleo de [la] fuerza
que disminuye el desgaste, aplicación de la
cuidadoso 1
fuerza automática
mediano 2 empleo normal
que aumenta el desgaste, aplicación de la
rudo 3
fuerza manual
Frecuencia de empleo H Número de empleos por unidad de tiempo
rara vez 1 >= 1x / semana, medición de referencia
mediana 2 >= 1x / día, muestras regulares
seguido 3 > 1x / dia, controles al 100 %
Sample:
C.C. 6312 / Op. 20 Maquina Hüller
Rev.:
8 09 / Fecha: 08.12.06
Pos. Medio de prueba Clasificación Tipo de Frec. uso
Caracteristica K O A H N Intervalo
cada [meses]
1 58.945 Anillo liso Ø58,96 -0,03 60 min. 1 2 3 2 12 12.5
2 8U8 Anillo liso Ø8U8 60 min. 1 2 3 2 12 12.5
3 8U8 A T=10,6+1 Espiga lisa Ø8U8 y T=10,6 +1 60 min. 1 2 3 3 18 10
4 66 37C 306154 Dispositivo 2,1+0,5x15° ±1° 60 min. 0
B): Special characteristics.
B.I. - Flexible plastic Pieces.
For the fixation of the piece additional points will be due to take from fixation or
subjection, to assure the stability the piece being simulated the theoretical assembly the
same one and that by design CAD indicates assembly position. These points can be of
fixation to body, rigid establishments, etc. And they must previously be accredited and be
decided with Metrology parts purchase VWM.
Like in parts of sheet metal (SpringBack), the pieces must have a recovery of
pretension/contraction in maximum free state of 1.0mm in all their form, before applying
the fixation elements to simulate the assembly.
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By no reason contact of the piece with the device will be due to have, in where the
surfaces to the assembly interact with other flexible and/or smooth pieces; An inserted one
will be due to decide with Metrology VWM the possible exceptions integrating that it
simulates a flexible joint.
It is necessary that in Vista pieces; the device has to have the ability to serve like control
fixture and miniCubing (adapting inserted tire irons or movable). Previous agreement with
Metrology purchasing parts VWM.
It is necessary that the device allows the measurement of internal zones in the piece when
are points of fixation or function and/or if internal changes are integrated that are
necessary to evaluate (through hollows or inserted tire irons, in where it allows to the
access of a measurement arm or auxiliary equipment, also SPC ports ).
B.II. - Joints.
The measures of function will be due to control defined by VWM (surfaces, cut,
punched and RPS of the components [If the joint drawing does not indicate it, will be due
to take like reference from the drawings from single parts]), to determine and to assure
does not influence of the joint process.
B.III. - Crystals.
Nets of support (RPS) in surface must have finished in sphere (to see fig. 7).
Apoyo RPS
con acabado
en esfera
Gap
Figura 7
B.IV. - Carpets and similars.
One will be due to accredit if points RPS (when it does not present/display them in
drawing ) according to the function of the same ones are required
They will be the only parts in where any Gap between piece and device will not be
required, that is to say, it will have to seat in all its forms on the device without generating
gaps. The measurements of the parts have to be with photogrammetric equipment.
The control of semicuts (courteous intervals), will be due to indicate with painted
lines interrupted
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The use of groups will have to be decided with Metrology VWM and Gap will be
applied to these for the inspection of the pieces.
B.V. - Rigid Pipes.
Two segments of control in straight zones of the pipe will be constructed.
They must have the circular form of the pipe including the surrounding tolerance of
the route (to see fig. 8).
The fixation points will be solely the reference the 0.0.0 and supports of fixation to
the body (previously accredited).
B.VI. - Flexible Pipes.
So many segments of control will be constructed as they are necessary in all the
forms and routes of the pipe to guarantee the stability of the piece.
The device contemplated the surrounding tolerance in the lateral faces of control
and in the inferior part it will have to be in the noun (to see fig. 9).
The fixation points will be solely the reference the 0.0.0 and supports of fixation to
the body (previously accredited).
It must have the ability to also verify the direction of the guides of subjection for clips.
Tolerancia
diametral
De envolvente Tolerancia
diametral
De envolvente
Figura 9
Figura 8
Figura a
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Annex 1 (title page).
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Annex 2. (Alignment, zones of function)
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Annex 3 (geometric levels and tolerances).
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Annex 4 (Profiles).
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Annex 5 (Path of pipes).
Annex 6 (Leaf with macros, image and protocol)
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Annex 7 (forms to present/display the concept of the device)
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Annex 7 (continuation…)
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Annex 8 (Check list for Control systems )
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Annex 9 (Methods and equipment alternative)
Annex 10 (Messpunkte and funktionmasse)
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Annex 10 (continuation)
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Annex 11 (Criteria for distribution of Messpunkte, parts of laminate)
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Annex 11 (Criteria for distribution of Messpunkte, nonmetallic parts)
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Annex 12 (Graphical of control)
Annex 13 (Numeric Part)
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Annex 14 (Following Sheet)
VII. - References.
Norm ISO 10012.
Procedimiento de Consorcio para primeras muestras 3.1_K-GQS-1_01_PS
Procedimiento de Consorcio para inspección de medios de control 3.4_K-GQS-1_02_PS
Manual Capacidad de medios Industria Automotriz
Formel Q-konkret
VDA 2: Quality Assurance of supplies
Norm de RPS, VW 0 10 55.
Manual de construcción de dispositivos VWA.
Norm sistemas de reporteo VW 10120 – 1
Norm VW 10136 Techniques for presentation in MB&C
Norm VDA 6.1
Norm TS 16949
Norm ISO 17025
Manual MSA
Ing. René López Pimentel 19/05/10
Lastenheft_dispositivos (Eng) Hoja: 29 De: 29
