Ausgabe Nr 6 Stand 01 07 2004 ALRT EEV Ki h allgemein vorlagen winword bestellvorschrift dot ALCZ PUR SQA BV Nr 1 309 915 237 Bestellvorschrift Order Specification Review 1 Subject Wire harnesses and shielded cables Page 1 of 7 Remarks released ALRT EEV Date 01 04 09 Signature Gez i V K mmerle ALRT QM P Date 01 04 09 Signature Gez Zwiehoff Zustimmung Agreement Distribution Alterations ALBD EAP ALBD PUR Alteration No Date Sign Issue Remark ALBD QAS 10EEV090304 03 03 09 Kp First Edition ALCZ EAP ALCZ PUR ALCZ QAS ALMA EAP ALNA EAP ALRT EEG ALRT EEV10 ALRT ELD ALRT ELT ALRT PUR ALRT QAS ALRT QSG Sicherung Storage ALRT EEV10 Date 03 03 09 Department ALCZ PUR SQA Name Lacina Phone 493 Alle Rechte Automotive Lighting Reutlingen GmbH auch f r den Fall von Schutzrechtsanmeldungen Jede Verf gungsbefugnis wie Kopier und Weitergaberecht bei uns BV Nr 1 309 915 237 Review 1 Bestellvorschrift Order Specification Page 2 of 8 Ausgabe Nr 5 Stand 20 12 2000 ALRT EEV Ki h allgemein vorlagen winword bestellvorschrift dot Content CONTENT 2 1 GENERAL 3 1 1 PURPOSE 3 1 2 CONFIDENTIALLY 3 1 3 NORMATIVE REFERENCES 3 1 4 QUALITY ASSURANCE 3 1 5 DUTY OF COMMUNICATION 3 1 6 ADDITIONAL AGREEMENTS 3 2 CRIMPING PROCESS MONITORING 3 2 1 CRIMP HEIGHT 3 2 2 TENSILE STRENGTH 3 2 3 TRANSVERSE MICRO SECTION 4 2 4 CRIMP WIDTH 5 2 5 CRIMPING FORCE MONITORING 5 2 6 CRIMPING TOOLS 5 3 WIRING HARNESSES FABRICATION 6 3 1 GENERAL INFORMATION 6 3 2 SINGLE COMPONENTS 6 3 3 100 ELECTRICAL FUNCTIONAL TESTING OF THE WIRING HARNESSES BY TEST BOARD 6 3 4 TEST BOARD VALIDATION AND MAINTENANCE 6 3 5 100 VISUAL INSPECTION 7 4 OTHER 7 4 1 MARKING AND LABEL 7 4 2 REWORKING AT HARNESS MANUFACTURER 7 4 3 WAREHOUSING CONDITIONS 7 4 4 PRODUCT RE QUALIFICATION 7 4 5 DELIVERY CONDITION 8 Alle Rechte Automotive Lighting Reutlingen GmbH auch f r den Fall von Schutzrechtsanmeldungen Jede Verf gungsbefugnis wie Kopier und Weitergaberecht bei uns BV Nr 1 309 915 237 Review 1 Bestellvorschrift Order Specification Page 3 of 8 Ausgabe Nr 5 Stand 20 12 2000 ALRT EEV Ki h allgemein vorlagen winword bestellvorschrift dot 1 General 1 1 Purpose The purpose of this procedure is to define minimum requirements of Automotive Lighting AL for suppliers of wire harnesses and shielding cables 1 2 Confidentially This specification must not be communicated to a third party without AL written consent 1 3 Normative references These normative references are cited at the appropriate places in the text The respective latest edition of the publication is applicable EN IEC 60352 2 Crimped connections 1 309 915 089 AL Order specification for shielded cables TYCO 114 18022 General guideline for application of contacts with open crimp barrels 1 4 Quality assurance See AL Quality assurance guideline for suppliers The quality target is ZERO failures The current valid minimum quality requirements are specified by Automotive Lighting 1 5 Duty of communication Any kind of change at product or process must be presented to AL and is only allowed to introduce after an appropriate release of AL This refers also to purchased components The supplier obliged his sub supplier to the same procedure 1 6 Additional agreements Any deviation from this order specification has to be approved in written form by AL 2 Crimping process monitoring Following criteria must be checked as a minimum and results have to be recorded 2 1 Crimp height Crimp height Statistical process control shall be implemented and Cpk shall be bigger than 1 67 Exceptions shall be approved in written form by AL Crimp heights adapted to the various cross sections shall be established by the terminal manufacturer Test conditions see EN 60352 2 2 2 Tensile strength Check of tensile strength at the beginning of each batch minimum Exceptions shall be approved in written form by AL Test conditions see EN 60352 2 BV Nr 1 309 915 237 Review 1 Bestellvorschrift Order Specification Page 4 of 8 Ausgabe Nr 5 Stand 20 12 2000 ALRT EEV Ki h allgemein vorlagen winword bestellvorschrift dot 2 3 Transverse micro section Transverse micro section one piece at the beginning of each batch minimum Exceptions shall be approved in written form by AL The degree of pressure of the crimp joint has to be assessed in the transverse micro section A homogenous gastight join must be produced between the single wire strands The single wire strands in the wire crimp must be pressed deformed and uniformly distributed 1 Burr height 2 Burr width 3 Crack The height of the burr at the bottom of the crimp barrel must not exceed the material thickness of the contact and the width must not exceed half material thickness Cracking formation is not permissible In conjunction with the smallest wire cross section within a given range there must be a gap of at least half thickness of the contact between the tips of the turned in crimp barrel and the bottom the wire barrel Crimp barrel Deformed wire strands BV Nr 1 309 915 237 Review 1 Bestellvorschrift Order Specification Page 5 of 8 Ausgabe Nr