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TABLE OF CONTENTS
OBJECT ....................................................................................................................................................................... 4 SCOPE .......................................................................................................................................................................... 4 APPLICABLE DOCUMENTS................................................................................................................................... 4 DEFINITION AND ABREVIATION ........................................................................................................................ 4 PROCESS SPECIFICATIONS .............................................................................................................................. 5 General ..................................................................................................................................................................... 6 Process qualification.............................................................................................................................................. 6 Process modifications ............................................................................................................................................ 6 Documentation....................................................................................................................................................... 6 SPC ........................................................................................................................................................................ 7 Identification.......................................................................................................................................................... 8 Traceability............................................................................................................................................................ 8 Calibration ............................................................................................................................................................. 8 Acceptability criteria ............................................................................................................................................. 9 Process parameter indicators ................................................................................................................................. 9 Quality target ....................................................................................................................................................... 10 5S......................................................................................................................................................................... 10 Human protection ................................................................................................................................................ 11 Environment protection ....................................................................................................................................... 11 Components and material qualification ............................................................................................................... 11 Technical specifications for each process step..................................................................................................... 12 Plastic injection.................................................................................................................................................... 12 Box design specifications for molding injection.................................................................................................. 12 Boxes and lids storage ......................................................................................................................................... 13 Grids casting ........................................................................................................................................................ 13 Strip rolling.......................................................................................................................................................... 13 Expanding............................................................................................................................................................ 13 Plates stacking ..................................................................................................................................................... 14 Curing .................................................................................................................................................................. 14 Plates storage ....................................................................................................................................................... 15 Separator assembly .............................................................................................................................................. 15 Quality of welding ............................................................................................................................................... 16 Intermediate storage............................................................................................................................................. 17 COS ..................................................................................................................................................................... 17 Short circuit test................................................................................................................................................... 17 Intercell welding .................................................................................................................................................. 17 Lid welding.......................................................................................................................................................... 18 Terminals welding ............................................................................................................................................... 18 Air pressure test ................................................................................................................................................... 18 Batteries storage .................................................................................................................................................. 18 Acid preparation and checking ............................................................................................................................ 18 First acid filling ................................................................................................................................................... 19 Formation............................................................................................................................................................. 19 Hydrometer insertion ........................................................................................................................................... 19 Plugs insertion ..................................................................................................................................................... 19 Second acid filling .............................................................................................................................................. 19 Washing and drying tunnel ................................................................................................................................. 20 Dielectric test in finishing line ............................................................................................................................ 20 OCV test ............................................................................................................................................................. 21 HRD test ............................................................................................................................................................. 21 Labelling.............................................................................................................................................................. 21 Final control before palletization......................................................................................................................... 21 Final control after palletization............................................................................................................................ 21 Final storage ........................................................................................................................................................ 21 Summary of the parameters ................................................................................................................................. 22 MATERIAL SPECIFICATIONS ........................................................................................................................ 23 General ................................................................................................................................................................ 24 Plastic parts.......................................................................................................................................................... 24 Lead ..................................................................................................................................................................... 25 Acid ..................................................................................................................................................................... 25 Additives.............................................................................................................................................................. 25 Other materials .................................................................................................................................................... 25 General specifications for 12V SLI Lead Acid batteries Version 1.4, 23/11/2007 2/30

Bushings .............................................................................................................................................................. 25 Labels .................................................................................................................................................................. 25 APPENDIXES............................................................................................................................................................ 26

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OBJECT This specification describes the Renault minimum requirements in terms of process methods and parameters that shall be fulfilled for every battery supplier of a Renault project. SCOPE This process control specification applies to all processes for the production of 12V lead acid SLI batteries. In the specification, each requirement is quoted according to a degree of flexibility (F0, F1). For instance: F0: Not negotiable, the requirement shall be fully complied for SOP. F1: if the requirement (target) can not be fully complied for SOP, it will be subject of a commitment of the supplier to reach this target. If there is no indication, F0 shall be used. For the main parameters, a matrix resumes the status page 22. The figure

is put in front of each chapter where a parameter is listed in the matrix page 22.

APPLICABLE DOCUMENTS ISO TS 16949 quality management systems - particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations Acceptability criteria for 12V SLI Lead Acid Batteries (Renault document). Production Part Approval Process PPAP Fourth Edition (AIAG) Measurement System Analysis (AIAG) DEFINITION AND ABREVIATION Interpretation Shall The emphatic form of the verb is used throughout his specification whenever a requirement is intended to express a provision that is binding. Deviation from a shall requirement may be considered if sufficient data is supplied to justify the exception.

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PROCESS SPECIFICATIONS

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General
Process qualification
Reference: ISO TS 16949 7.5.2 Each process shall be qualified, it means: The criteria for review and approval shall be defined The equipment shall be approved and the personnel trained and qualified All the specific instructions shall be available Evidence of this qualification shall be available on supplier request (operator training, machine and product capability, machine specification and PV for reception)

Process modifications
Any process change shall be validated by RENAULT according to ANPQP. Any major change need a new qualification of the batteries (see table page 21) Each equipment or line (line number) where the Renault batteries are manufactured shall be declared to RENAULT. Any change shall be validated.

Documentation
Each manufacturing operation shall be described within an instruction. Documents (could be some extracts of the working instruction) shall be put up on the station (visual management). All documents shall be managed (creation, validation and modification).

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SPC
SPC has to be used on several process steps: The minimum process steps monitored with SPC are indicated within the following matrix: Process Oxide milling Strip rolling Expended grids Punched grids Casted grids Pasting Drying tunel Curing Terminal welding Acid filling Final Parameter Free lead Thickness Strip width Width Height Thickness Width Height Plate thickness Plate weight Plate weight Plate thickness Humidity Free lead Humidity Terminal height Acid level OCV HRD

The supplier shall use as acceptance criteria for evaluating the processes (See PPAP Fourth edition from AIAG): Cpk > 1,67 1,33 Cpk 1,67 < 1,33 Interpretation The process meets the acceptance criteria The process may be acceptable. Contact the customer representative for a review of the study results The process does not meet the acceptance criteria.

Processes with one sided specifications or non normal distributions: The supplier shall determine with the customer, alternative acceptance criteria for processes. Tools used for measurement (see Measurement System Analysis from AIAG): All tools used for product inspection and all process indicators or gauges (temperature displays) shall be calibrated on a regular basis (yearly). Gage R&R has to be demonstrated for all tool used for product inspection (i.e. Control Plan).

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Identification
Each battery part (raw material, grids, plates, terminals, plastics parts..) shall be identified in the storage area and on the manufacturing line thanks to a visible part number (labels, dedicated areas).

Traceability
The manufacturer shall maintain the full traceability for each battery, it means: The manufacturer shall be able to recover the date code of all components and raw materials used in a battery and the manufacturing date , shift and line number (plate assembly, battery assembly, formation, finishing). The manufacturer shall recover all the batteries sent to RENAULT made with an identified part or raw material. At the minimum the date code of the following products shall be recorded and the supplier shall recover all the batteries built with a specific lot of material: Lead for oxide Lead for strip Lead for grid (casting) Lead for Strap (COS) Acid Separators Lids, boxes, plugs Lot of paste (F1) Lot of plates after curing (F1) Lot of lead strip (expending) (F1) Lot of grids (casting) (F1) Magic eyes

Calibration
All tools and indicators used during the process (temperature, current, voltage, air or gas pressure indicators), shall be controlled by metrology department at least every year. A visible label shall indicate the last and next calibration dates. Tools and equipments which are used during the process to pronounce a status on a battery (accepted or rejected) must be calibrated by a specific laboratory connected to an accredited company. The frequency shall be demonstrated.

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Acceptability criteria
The supplier shall write a document describing the acceptability criteria for each process step and each battery element. Each criterion shall be defined with: The target The limit of acceptation The defect Drawing and pictures shall be used. All details shall be mentioned (measurements, ).

Process parameter indicators

All the process parameters (temperature, pressure, duration) shall be set by using a unique set value (indicated within the work instructions). A tolerances can be add but only used for the parameter value checking. Example: Set value for melting pot: Set value 440 C Best practice Tolerances +/- 10C Bad practice Set value 430C to 450C

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Quality target
At least the following indicators shall be put in place on the manufacturing line with quality targets reviewed every year at the minimum. Those indicators shall be available for Renault. Operation Plastic injection: Grid casting Expending Plates pasting (on stacking station) Enveloping COS Short circuit test Air leakage test Terminal welding Formation 2nd acid levelling OCV HRD High voltage Final inspection Indicator ppm of defective parts or wasted plastic ppm of defective parts ppm of waste material ppm of rejected plates or weigh of lead ppm of rejected plates or weigh of lead ppm of rejected cells (due to bad COS or bad enveloping) ppm of double plates ppm of rejected batteries ppm of rejected batteries ppm of repaired terminals or % of defective terminals ppm of batteries out of specif after formation ppm of rejected batteries ppm of rejected batteries ppm of rejected batteries ppm of rejected batteries ppm of rejected batteries

On all process steps, rejected parts shall be counted and registered.

5S
5S program shall be engaged by the supplier in the entire factory. All the work stations shall be free of dust and foreign particles. Tools shall be identified on each station. All the components (boxes, lids, lead ingots.) shall be identified. On each line the product in progress shall be identified (at the beginning of the line). Visual management shall be used on all process steps (acceptability criteria, work instructionshall be visible on station).

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Human protection
In order to protect employees against lead, acid and chemical, an adapted and strong policy for human protection shall be implemented. Standards*: European: European directive 82/605/CEE US standards: OSHA (Occupational Safety & Health Administration) 200 Constitution Avenue, NW Washington, DC 20210 * Other regulations could be used (local standards). The supplier shall retain documentation relative to human protection which explains the rules to be used by the employees. The most important rules are: To maintain good ventilation on the entire factory To put in place a specific house keeping on the floors, machines and benches. Employees shall wear gloves, glasses, mask Food and beverage shall be forbidden in the production area Blood monitoring

Environment protection
The supplier shall retain documentation relative to environment protection which explains the rules to be used in the entire factory. Material recycling shall be managed and planed.

Components and material qualification

Each supplier, bulk material (lead, acid, chemical) and components (bushing, boxes, lids) must be chosen and qualified according to automotive standards (like Production Part Approval Process PPAP).

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Technical specifications for each process step

Each process step is submitted to F1 F0. For the value, please report to the matrix page 21.

Plastic injection
Dielectric test for battery box

A dielectric test shall be performed on the injection points. The process parameters depend on the origin of the PP sourcing (pure or recycled) see matrix page 21. Pressure test

In order to detect the possibility of void, specific pressure test shall be applied on 100% of the boxes (F1). This test shall not impact the box integrity (deformation). Manual rework of plastic parts Use of a knife on the welding surface: forbidden Use of a knife on other areas: allowed but it implies that the dielectric test follows this operation

Box design specifications for molding injection

Injection points positions:

The injection points shall be located on the separation areas (F1). The size of the injection nozzles shall be reduced (F1)

KO

OK

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Boxes and lids storage

The storage conditions shall preserve the boxes and lids against mechanical constraints (deformation) and dust. Grids casting The date of use shall be managed. A specific label which indicates the minimum and maximum date of use shall be used. The spray (mould lubricant) shall be qualified.

Strip rolling
The strips shall be stored on specific pallets free of metallic parts or nails which can damage the lead strip. The date of use shall be managed. A specific label which indicates the minimum and maximum date of use shall be used. A maximum of 2 rolls can be superposed on a same pallet.

Expanding
Strip welding (end of roll) This chapter describes the welding process between 2 rolls during lead strips loading. Cold welding: Prior to use the welded strip for expending, a qualification shall be performed to prove the strength and quality of the welded area. Hot welding: The plates made with hot welding strip shall be removed prior to dry (the metal properties have been changed). The part of the strip shall be identified prior to use (paint for example). Welding performed with adhesive tape The plates made the adhesive tapes shall be removed prior to dry. The part of the strip shall be identified prior to use (paint for example). The identification shall guaranty that all grids made with non homogeneous metal are removed. Strip cleanliness: During the replacement of the rolls, the strip shall not touch the ground to avoid any pollution with foreign material.

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Line start up During each star up of the line, the quality of the grid can be poor (broken wires). A specific process shall be applied in order to identify, inspect and remove all defective part of the grid strip before drying. Stretch test on grids: A mechanical strength shall be applied on the grid. The method shall be described and the Renault acceptability criterias shall be respected (no broken wire). For example:

+ 15 %

Plates stacking
All defective plates shall be removed from the pallets before going to curing. A specific attention shall be paid concerning the manual handling and the use of a robot (to avoid folded corners, bended wires).

Curing

The target is computerized chambers with automatic temperature and humidity control (F1) In case of manual management, the temperature and humidity shall be controlled (recorded) on regular basis After curing a specific test shall be performed on plates in order to verify the paste adherence on grid. Vibration test is recommended. Test parameters and acceptability criterias shall be described for each method.

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Plates storage
The stored plates in a pallet shall not be in contact with the upper pallet. Storage conditions shall be defined within an instruction. They shall preserve the plates against mechanical constraints (bending, folded corners). If the pallets are iron made, a specific surface treatment shall be applied to avoid any iron oxide. The traceability shall be maintained during storage. FIFO shall be put in place.

Separator assembly

Separator rolls storage shall avoid any mechanical constraint and pollution. When the roll is loaded on the equipment, the PE strip mustnt touch the ground. A specific optical or mechanical mechanism shall be used on the equipment in order to avoid double plates. The PE strips used for enveloping shall be free of defect (holes normally identified with spray marks), or the enveloping equipment shall be able to detect the holes or spray mark and stop the production in order to remove the strip impacted.

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Quality of welding
A specific test shall be performed on the welded separators. This test shall be defined within an instruction. We show a specific test as an example, any other method can be proposed. The process shall be characterized (SPC analysis and Cpk calculation). The target and tolerances shall be set and used for the test.

One method (for example)

50 mm

Welding

X kg

The welding strength shall be defined

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Intermediate storage

In order to avoid any manual handling operation an automatic conveyor shall be used between the stacking machine and the COS machine (removal of the intermediate storage) (F1)

COS
Lugs fluxing shall be checked on a regular basis on real plates (regular fluxing on all lugs, height of flux along the lugs). The flux shall be referenced and qualified. The COS quality shall be checked by performing a longitudinal cross section on a strap. Lug penetration, quantity and size of bubbles shall be specified.

Short circuit test

The voltage applied shall be between 0,8 kV and 1,4 kV. Each defective element shall be analysed in real time in order to react on the line. The defects shall be recorded in real time and a target shall be defined. The handling procedure used for defect detection shall be described within an instruction. After short circuit detection, when no defect is found during the manual analysis, the complete cell impacted shall be replaced.

Intercell welding
The equipment shall be calibrated. In case of technical impossibility, the calibration shall be replaced by an experiment plan performed on a yearly basis (in order to determine the right parameters value). The parameters (current, pressure) shall be determined by performing an experiment plan. A specific shear test shall be performed. This test can be destructive (performed on a regular basis) or non destructive (performed on 100 % basis). In this case, it shall be demonstrated that this test does not damage the intercell welding.

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Lid welding
The machine parameters (temperature, duration) shall be defined for each reference of lid and box and that for each different material used (if it is the case). An experiment plan shall be conducted in order to define the best set of parameters. The design of the couple lid/box shall be done in order to avoid any shift which is more than of the box wall thickness. The lid shall be cut in order to check the welding on all the surfaces in contact. The observation of small parts of the lid is not enough. The cells shall be inserted in order to be representative to the real conditions. A complete battery shall be cut at least each shift. The acceptability criteria shall be defined.

Terminals welding
Terminal welding shall be performed with an automatic machine which authorizes time and temperature control. The height of the welded area shall be defined with a min and max value. The max value is indicated in order to avoid any conicity problem or rough terminal surface. The min value acts on the mechanical strength and current capacity. The height of terminals shall be measured by automatic machine on 100% of the batteries. Manual rework (welding) or second welding is forbidden.

Air pressure test

100% of the batteries shall be tested for leakage (air pressure test). The conditions are defined in the matrix page 21.

Batteries storage
Batteries storage shall be described within a specification. The storage conditions shall preserve the batteries (terminals) against mechanical constraints. A separator shall be used between two levels of batteries. No more than 3 batteries layers shall be stacked.

Acid preparation and checking

A digital densimeter (hydrometer) shall be used for all acid inspection. The temperature shall be specified and checked.

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First acid filling The system shall avoid any overflow of acid.

Formation

The formation room shall be well ventilated. Specific plugs shall be used to avoid any acid overflow. Specific plugs shall be used in order to avoid any overflow of acid (F1) The formation program shall be controlled by a computerised system. A water cooling system shall be used (F1). The temperature of the acid shall be monitored in real time. A temperature sensor shall be used for each circuit of batteries (F1) The historic of each formation run has to be kept for one year (current, voltage and temperature). The maximum temperature of the acid during formation shall be 65C max. Straps used to connect the batteries shall be verified on a regular basis. The shape of the connections shall preserve the terminals against mechanical damages, sparks, and black marks (if presence of acid). Storage shall avoid any foreign material into the batteries (iron oxide, .).

Hydrometer insertion

The hydrometer shall be set with an automatic machine (manual hammer is forbidden), or by using a calibrated electrical screw driver (F1).

Plugs insertion
If screwed plugs are used, calibrated electrical screw driver shall be used.

Second acid filling

This station requires a 100% automatic level control device independent from the filling and levelling device with level measurement tolerances of +/- 2mm. Renault asks for a capability study of the device. If the washing is performed with temporary plugs, the height of acid inspection shall be performed after washing (F1).

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Washing and drying tunnel

The station is automatic and requires a continuous ph monitoring for the rinsing tank. The temperature of the water shall be checked. No trace of liquid is permitted on finished batteries (F0).

Dielectric test in finishing line

The test is performed 100% for the bottom and for the lid to box weld. The conditions are defined in the matrix page 21.

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OCV test

This control is automatic and with a 100% frequency OCV compared with minimum and maximum voltage thresholds. The thresholds are set in order to ensure the batteries to respect the Renault delivery conditions. 100 % of all the OCV values shall be recorded.

HRD test

The control is automatic and with a 100% frequency. The test shall be performed at constant current (F1). The minimum discharge current is defined as follows: Discharge Current: 0,6 Icc I HRD Icc The min voltage shall be defined The maximum discharge capacity during HRD test mustnt represent more than 1% of the nominal capacity. 100 % of all the values shall be recorded

Labelling
The reference and label location on the batteries shall be defined within a drawing or specification. The label position shall be defined with tolerances.

Final control before palletization

The inspection of the plugs, labels and magic eye is performed by a video camera. All batteries shall be inspected on 100% basis (visual).

Final control after palletization

A final inspection shall be performed on each pallet (visual and electrical). A specific check list shall be used according to the control plan.

Final storage
The batteries shall be stored inside in order to protect them against dust, sun, rain and extreme temperature.

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Summary of the parameters

Process steps
Dielectric test for injection point

Parameters
Fr pure PP: 10kV 5% 30kV 100% For recycled PP: 30kV 100% 100 % of the boxes are checked The injection points shall be located on the separation areas Automatic chambers (computerized system) Double plate detection An automatic conveyor is used for transportation to the COS station. Voltage shall be between 0,8 kV to 1,4 kV 100% leakage control with the following parameters: Test Pressure 250 mbar Test Pressure 300mbar Acceptable pressure drop 10mbar Acceptable pressure drop 5mbar Specific plugs shall be used to avoid acid overflow Water cooling Computerized system Temperature monitoring on each circuit Manual hammer is forbidden level measurement tolerances = +/- 2mm. Independent machine Ph monitoring of the last bath The test is performed 100% for the bottom and for the lid to box weld - With the following features : Duration 2s Voltage 6kV Duration 2s Voltage 12kV This control is automatic and with a 100% frequency The values are recorded in order to perform SPC The control is automatic and with a 100% frequency - The minimum discharge current is defined as follows : Discharge Current: 0,6 Icc IHRD Icc The values are recorded in order to perform SPC

F0
X

F1

Supplier status

X X X X X X X X X X X X X X X X X X X X

Pressure test Box design versus injection points Curing Separator assembly Short circuit test Air pressure test for green batteries

Formation

Hydrometer Second acid filling : Acid level checking Washing and drying Dielectric test in finishing line :

X X X X X X

OCV test HRD test :

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MATERIAL SPECIFICATIONS

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General
Material modification All material shall be declared by the supplier. Any modification of material reference or material supplier, qualification tests shall be performed again following the matrix page 21. If the material modification impacts the process (ie for lid and boxes), the process qualification shall be demonstrated.

Plastic parts
Boxes, lids, plugs, double lids: Poly propylene polyethylene (P/E): Flammability: All material shall be 94V0 or equivalent standard. Mechanical and chemical properties: Incoming inspection shall be performed on P/E on regular basis. The sampling rate and frequency shall be justified by the supplier. For a minimum, the following material specifications shall be given and checked during incoming inspection by the supplier. Melt flow index Hardness Elongation strength Recycled materials The percentage of recycled material shall be mentioned by the supplier (IMDS file) Mechanical and chemical properties shall be given for recycled material. All finished materials build with recycled P/E shall be fully compliant with the RNDS 36 11 000 (last revision). Additional tests to be performed: Dielectric test at 100% of the product See process specifications for parameters. Storage conditions The storage conditions shall preserve the plastic parts against water, dust and mechanical constraints (indoor only).

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Lead
Lead composition and impurities shall be declared by the supplier. The materials mentioned within the matrix (appendix 27) shall be checked during incoming inspection by an adapted method. The sampling methodology shall be defined (number of samples, number of ingots). Each sample shall be identified (lot number, date).

Acid
Acid composition and impurities shall be declared by the supplier. The materials mentioned within the following matrix shall be checked during incoming inspection by an adapted method.

Additives
For all additives, general specifications shall be provided by the supplier. The materials mentioned within the following matrix shall be checked during incoming inspection by an adapted method.

Other materials
The specifications of all materials used in the batteries construction shall be defined: Spray for casting (grid, COS) Separator Pasting paper Demineralised water Flux for COS

Bushings
Bushings shall be made with cold forged process. The brand and reference shall be provided by the supplier. Any modification of the bushing supplier, reference, needs to be declared to Renault and new batteries qualification to be provided.

Labels
Labels shall be resistant to solvent test, acid and UV (see RNDS standard).

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APPENDIXES Material composition matrixes

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Lead composition: Lead for oxide Recycled Calcium Aluminum Antimony Arsenic Tin Silver Iron Copper Nickel Cobalt Zinc Bismuth Cadmium Manganese Silica Platinum Vanadium Titanium Tellurium Calcium Actinium Selenium Mercury Lead for COS Lead for Expending (positive) Lead for Expending (negative)

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Acid composition:
Material and impurities Acid 1 Acid 2

Iron Sulfurous acid Antimony and Arsenic Manganese Nitrates Ammonium Chloride Platinum Organic matter Fixed residues Zinc Selenium Nickel Copper Cobalt Al Vanadium Cadmium Chromium Mercury Other metals (total)

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Additives composition:
Material, impurities, properties Fibers Carbon black Vanisperse BaSo4 Sodium sulphate Others

Iron Antimony and Arsenic Manganese Nitrates Ammonium Chloride Platinum Organic matter Fixed residues Zinc Selenium Nickel Copper Cobalt Al Vanadium Cadmium Chromium

Separators:
Parameters Width Thickness Electrical resistance Elongation Puncture resistance Volume porosity Acid weight loss Shrinkage Oil content Iron Manganese Copper Chloride Defect per rolls (spray marks) Specifications

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Pasting paper
Parameters Weight / m Thickness Tensile strength Air permeability Specifications

Demineralised water:
Parameters pH Electric conductivity Impurities (chloride and heavy metals) Specifications

Flux for COS

Parameters Flux reference Thinner reference Specifications

Other material
Parameters Specifications

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