Special Characteristics Training GS0400

1. Special Characteristics Training GS0400 powersolutions.danfoss.com

2. Academy special characteristics class- Course options Use Controls atLower Left To select Training level (Must be in Presentation Mode)

3. ISIR GS0015 Control Plan GS0012 Capability GS0007 Gage R&R GS0010 PPAP GS0008 P-FMEA GS0006 Process Map GS-0063 Special Char. GS0004 D-FMEA GS0003 QFD GS0031 Product Test GS0017 Steps to Quality

4. Agenda • What GS-0004 Covers • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

5. What is the purpose of special characteristics? • Focus Special Attention on the “Vital Few” Things which make a Difference to our Customers • Formally Communicate these “Vital Few” Characteristics and their Required Process Controls throughout the Supply Chain • Promote Design For Manufacturability (DFM) through Simultaneous Discussions regarding Design Tolerances and Manufacturing Variation • Aid in Economically Manufacturing Quality Products that meet Customer Expectations • Require Greater Production Control/Monitoring of the “Vital Few” • Facilitate Knowledge Management through time (both Product Engineering & Process Engineering)

6. What does “Special Attention” mean? • Focused Attention during the Design and Processing • Data based Design For Manufacturability (DFM) • Drives Severities from DFMEA into PFMEA • Required Levels of Process Capability and Control • Gage R&R, Capability exceeds • Features included on Control Plan with appropriate Statistical Controls • Indicate importance of the features throughout the life of the product/process (Knowledge Management) • Ensure Extra attention is made during review of PPAP/Change Management document review

7. “Vital Few” Aren’t they All important?! • Yes – All we must strive for all features to always be “In Print” • Key Characteristics are those characteristics that being “On target with Minimum Variation” provides better satisfaction than just being “in Print” • Features not important for customer safety or satisfaction can be handled differently for more economical manufacturing • Focusing on All is like Focusing on None!

8. Why “Vital Few”?How many should we have?Lets look at the Loss Function Total Product Dis-Satisfaction Dis-Satisfaction Due to Cost “Loss” Performance Dis-satisfaction 0 All Number of Special Characteristics

9. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

10. Scope & Application • GS-0004 Creates Special Characteristics • Safety Characteristics • Key Characteristics • Process Characteristics • Standard Characteristics • GS-0004 applies to • Danfoss Power Solutions Globally • All New Designs • GS-0004 Defines • Selection • Identification • Documentation • Required Manufacturing Controls

11. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

12. S DefinitionSafety Characteristics • Safety characteristics are those characteristics/features which have the potential to affect safety. • When defining safety characteristics the safety of all personnel involved in the product test, vehicle commissioning, and end use of the product need to be considered. • Safety characteristics should be controlled through • robust safety margin for normally expected process variation AND • manufacturing error-proofs that detect/prevent abnormal process variation which could significantly reduce safety margin. • Safety characteristics will be identified on the engineering drawing with a pentagon with an ‘S’ inside it.

13. Definitions • Normally expected process variation • The amount of manufacturing variation when the process is maintained under the defined process controls. • Note that for some process controls normally expected variation will include some out of specification • Safety margin • The difference between the extreme of normally expected process variation and the point at which a safety loss could occur • Abnormal process variation • Unusual Manufacturing variation created by a process failure • Broken tool, missed heat treatment, etc • Error-proof • Device or method which Detects and contains/corrects abnormal variation

14. Definitions- safety margin Point at which Safety is Impacted Lower Specification Limit Upper Specification Limit Design Specification Safety Margin Abnormal Process Variation Examples Normally Expected Process Variation Note: Normally Expected Process Variation Shown is for a process with 100% Sort and a GRR of 50%

15. K DefinitionKey characteristics • Key characteristics are defined to be those characteristics for which the normally expected process variation affects product function/customer satisfaction • Customer can distinguish product differences due to the variation of a key characteristic within specification • Customer satisfaction is increased when these characteristics are maintained on target with minimum variation • Key Characteristics will be identified on the engineering drawing with a pentagon with a ‘K’ inside it

16. P Definition Process characteristics • Process Characteristics are features/characteristics which do not directlyaffect the function of a product but are important for success of downstream manufacturing processes • Tolerances held tighter than needed for product function to accommodate robotic assembly • Internal Customer satisfaction depends on these features being in specification • External Customer Satisfaction (Product Function) does not require the tolerance to be held this tightly • Process characteristics will be identified on the engineering drawingwith a pentagon with a ‘P’ inside it

17. Q: Why did we create a Process Characteristic A: Some areas do automated assembly. For automated assembly you oftenhave a robot grabbing the part on a non-functional area and then assembling into a tight clearance Robot Grabs d2 and installs spool into bore If Concentricity ( ) of d2 to D1 is not important for function but is necessary for Automated assembly. Concentricity of d2 to D1 would be a Process Characteristic

18. Process Characteristic Example Endcap A-B machining operation in a cell bolt holes Machined in A-op and used for location on the B-op. For the process we need to the holes to be + .1 and a True Position of .1mm Engineering Drawing (Function) says +.13mm and True Position of .75mm Should we Modify the Engineering Drawing and Use a P? No – If it is within your own processes it should be done within your own process controls (e.g. cell control plan/process drawings, etc) Not with the Engineering Drawing

19. DefinitionStandard characteristics • The majority of features in a good design are standard features. Standard features must be maintained within specified limits • Standard Features are those for which reasonably anticipated manufacturing variation is unlikely to significantly affect a product’s safety or function • Customer satisfaction does not change based on where a standard feature is within its tolerance range • Standard Features do not have a symbol No Symbol

20. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

21. Responsibility • Product Engineering is responsible for identifying and classifying Safety and Key special characteristics as soon as practical in the design process • Product Engineering Managers in individual areas shall be responsible for ensuring Special characteristics are correctly documented on Engineering drawings and specifications • Process characteristics, if required, are to be identified by Process Engineering • Operations and Purchasing Managers in individual areas shall be responsible for ensuring adequate process controls are put in place for special characteristics

22. Assigning special characteristics • Design Engineering Assigns Safety and Key Characteristics Utilizing the Design FMEA as soon as possible in the Design Process • Safety Characteristics • Severity ≥ 9 • Key Characteristics • Severity ≥ 5 & Occurrence ≥4 • Safety and Key Characteristics • Severity ≥ 9 & Occurrence ≥4 • Manufacturing Engineering Assigns Process Characteristics

23. S Assigning Safety CharacteristicsWithin propel • Assignment of Safety Characteristics Requires Special Controls • Follow your local BA rules (usually requiring Director of Engineering Approval) before assigning Safety characteristics to drawings.

24. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

25. Determining Special Characteristics • First Use Design FMEA • Severity and Occurrence Ratings • Special Characteristics Table • Then Evaluate “Border” cases using Loss Function Method • Continuous or Step Loss • No Margin, Small Margin, Large Margin • “Border Cases” from Severity and Occurrence Table • Covered in “Expert” Training

26. Determining Special CharacteristicsUsing DFMEA Severity & Occurrence (S x O)

27. DFMEA SeverityReference GS-0002/HPP 200

28. DFMEA OccurrenceReference GS-0002

29. Applying Judgement • In addition to the use of DFMEA Severity and Occurrence, Key characteristics can be determined using the quality loss function logic defined in Appendix ‘C’ of GS0004 • Quality Loss Function logic can be an effective way to assess “border” cases from the “S x O” method (i.e. Occurrences of 4,5 & 6 and Severities of 5 and 6) to determine if classification as a “Key” characteristic is really warranted • Engage an expert in Quality Loss functions • DFMEA facilitators • Quality Engineers

30. Determining Special CharacteristicsUsing DFMEA Severity & Occurrence (S x O) Border Cases

31. Special Characteristics Applied to Material or Heat Treatment Specs Special Characteristics may be applied to material and heat treatment specifications • Key if DFMEA severity ≥ 5 and occurrence ≥ 4 • DO NOT base occurrence (design margins) on an assumption of the supplier using the wrong material or a required heat treatment is omitted • For example: The part will break if the supplier uses the wrong material so I will make it a Key Characteristic • Loss Function Method is a very good for material and heat treatment Specifications.

32. Special Characteristics Identified onMaterial or Heat Treatment Specs • The special characteristic must be assigned to something that is measurable (hardness, case depth, tensile strength, etc.) and not to the entire specification Material: ASTM A536 Grade 65-45-12 Hardness: 156-217 BHN

33. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

34. Special Characteristics identified onDanfoss Power Solutions engineering drawings • A pentagon with an “S” for Safety, a pentagon with a “K” for key, or a pentagon with a “P” for process shall be placed on the technical document by each characteristic designated as a special characteristic.

35. Special Characteristics identified onDanfoss Power Solutions engineering drawings • In the case that a feature is described by multiple callouts a special characteristic designation is required for each callout.

36. Special Characteristics identified onDanfoss Power Solutions engineering drawings • In cases where a characteristic is both a safety and a key the special characteristics are to be designated as shown in Fig 3. The order (K first or S first) is not important

37. Error-Proof Documentation • Add the Note “Special Characteristics per GS-0004” on the first page of the Drawing/Specification • Customer Importance Table (CIT) must be on First Page of all drawings and relevant specifications • Typical drawing formats shown Below • May be included on other pages

38. Special CharacteristicsLocation Table An Optional Location Table on Sheet 1 defines wherespecial Characteristics are Located Helpful to make sure that none are missed This drawing has 36 Specials Located on 5 Sheets Sheet # Location x QTY

39. Correctly Showing a Completed Drawingwhich has no Special Characteristics • Add the CIT Table to the First Page of the Drawing/Specification even if there are no Special Characteristics • Add the Note “Special Characteristics per GS-0004” on the first page of the Drawing/Specification • Add the CIT Table and a Blank Special Characteristics Table to the first page of the Drawing/Specification

40. Agenda • GS-0004 • Purpose • Scope & Application • Definitions • Responsibility • Determining Special Characteristics • Documentation • PPAP and Process Control Requirements • Drawings Created Before GS-0004E • Summary/Q&A

41. Process Requirements • S, K, &/or P characteristics Must be Identified on PFMEA and Control/Gauging Plan including control method • S Requires Error Proof Control method • K Requires Statistical Control Method • Therefore statistical Gage R&R and Capability studies must be completed and exceed minimum requirements • P Does not require a specific control method

42. S Production control methodsAcceptable for safety characteristics • The Manufacturing Focus for Safety Characteristics is to ensure that abnormal variation (i.e. “Special Cause” process failures ) that significantly reduce or eliminate an adequate design margin do not occur • What is a abnormal variation • Process Goes out of control and produces “unexpected” variation

43. Definitions- Safety margin Point at which Safety is Impacted Lower Specification Limit Upper Specification Limit Design Specification Safety Margin Normally Expected Process Variation Abnormal Process Variation Note: Normally Expected Process Variation Shown is for a process with 100% Sort and a GRR of 50%

44. Example Special causes(Sources of unexpected variation/Abnormal process variation) • Wrong Material/Heat treatment • Wrong raw material received / selected • Wrong or interrupted heat treatment • Doesn’t get to proper temp due to thermal capacitance • Tool Set-up Errors • Wrong off-set entered in machine • Wrong insert • Wrong Radii • Broken Tools/Wrong Tools • Broken Fixtures • Bent dowel pins • Missing rest pads Note that special cause failures affect all Parts until corrected. They can create a BIG problem but they are easier to detect because all parts are affected

45. Example special causes(Sources of unexpected variation) • Missed Operations • Missed heat treat altogether • Missed test / adjustment process • Unplanned process stoppages • Delay prior to quench • Incomplete operations • Machine restart in middle of program • Undetected Maintenance Issues • Broken Valves • Furnace Filters Note that special cause failures affect all parts until corrected. They can create a BIG problem but they are easier to detect because all parts are affected

46. S Suitable control plans for • Safety characteristics require an Error proof • What is an Error proof? • A process or device that ensures either • Special cause errors do not take place or • If it has occurred, does not allow the next process step to take place or • Produces an immediate error signal and corresponding non-conforming material control in the event of a special cause errors • What does an error proof Not do • It is not intended to control common cause (normally expected) variation

47. S Establishing good error proofs • Understand the ways the process could fail and produceAbnormal variation • Fishbone diagram (5M/E) • PFMEA • Second determine best way to control • Error proof types • Type 1 Error-Proof: Prevent from happening • Type 2 Error-Proof: Detect before passing from operation • Type 3 Error-Proof: Detect at next (or Downstream) operation

48. S Example error proof control methods(100% Preventing or detecting unexpected variation) • Wrong material • Bars: Each bar verified as loaded in machine properties or color code • Castings: Lot material certifications • Wrong or inadequate heat treatment • Samples inspected from each lot • Missing heat treatment • Inspection at next operation • Broken tools • Inspect 1st piece/last piece • Broken tool Detection (Laser or Load Monitoring) • Wrong tool/wrong insert/wrong offset • Inspect 1st piece • Barcode at pre-setter/scan at installation • Tool holder only accepts correct insert • Delay before quench • IR temperature reading at quench

49. S Process control requirements • Safety Characteristics / PPAP Requirements • Identified as safety on PFMEA & assigned severity = 10 • Identified as safety on Control plan with an error proof (Poke-Yoke)documented on control plan

50. K Process control requirements • Key characteristic / PPAP requirements • Identified as “Key” on PFMEA & Assigned severity = 8 • Production control with variable gauging & GR&R<20% completed per GS-0010 • Capability studies completed per GS-0007 with capability Cpk > 1.33 • Identified as “Key” on control plan (symbol or words) • Statistically valid control method which will maintain Cpk>1.33