MAZZETTO SANDRA - SANDRA.MAZZETTO@FIAT.

COM
MAIORANA GIOVANNI - giovanni.maiorana@fiat.com

FPW.IFN053
Powertrain Class: O1IF
KEY CHARACTERISTICS DESIGNATION
SYSTEM - KCDS
Page: 1/20

Date: 20 JUN 2014

POWERTRAIN STANDARD

1 PURPOSE
The present Standard aims to describe methodologies and application to:

 classify the product in order to define the belonging "part level";

Supervisor

 classify the product characteristics and process parameters to ensure manufacturability and
customer satisfaction.
Author

2 SCOPE
The Standard applies to all new products (projects and/or processes) and variants of engines and
transmissions, both for internal projects and projects developed with suppliers.

Livello
Data Descrizione modifica
modifica
1 05/05/2011 First issue: supersedes Procedure FPT.IFN053.
2 26/06/2012 Revision following document demerger. Fully revised.
3 20/06/2014 Inserted references to Purchasing Specifications FPW9.01120/09.
Supervisor department
Author Department

ANY PRINTED COPY IS TO BE DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE
CONFIDENTIAL:
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT
BY FIAT GROUP AUTOMOBILES SPA
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE MOST UPDATED OF ITALIAN AND ENGLISH EDITIONS
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KEY CHARACTERISTICS DESIGNATION SYSTEM - KCDS

TABLE OF CONTENTS

1  PURPOSE .......................................................................................................................................... 1 
2  SCOPE ............................................................................................................................................... 1 
3  REFERENCES ................................................................................................................................... 3 
4  ACRONYMS / TERMS ....................................................................................................................... 3 
4.1  Acronyms ........................................................................................................................................... 3 
4.2  Terms ................................................................................................................................................. 4 
5  PRODUCTION PROCESS VARIABILITY.......................................................................................... 4 
6  GUIDELINE FOR DESIGN CHARACTERISTICS CLASSIFICATION .............................................. 5 
6.1  Tools ................................................................................................................................................... 5 
6.2  Project characteristics classification definition ................................................................................... 6 
6.3  Definition of characteristics impact..................................................................................................... 6 
6.4  Methodology for design characteristics classification ........................................................................ 7 
6.5  Special case ....................................................................................................................................... 9 
7  MATCHING BETWEEN DESIGN CHARACTERISTICS CLASSIFICATION AND CAPABILITY
TARGET ........................................................................................................................................... 11 
7.1  Management of PQC-S, PQC and CPC not subject to requirements in terms of capability ............ 13 
7.2  Management of not machined dimensions, related to critical or important characteristics ............. 15 
7.3  Note about material for buy item ...................................................................................................... 15 
7.4  Management of project critical characteristics in assembly processes ........................................... 15 
7.4.1   Tightening torques for mechanical plants (see par. 6.4, table 4) ..................................................... 15 
7.4.2    Clearances, alignment, seal couplings ............................................................................................ 16 
8  GUIDELINE FOR COMPONENTS CLASSIFICATION (PART LEVEL) .......................................... 16 
8.1  Tools ................................................................................................................................................. 16 
8.2  Component classification (part level) ............................................................................................... 16 
8.3  Links with service classes (CF) ........................................................................................................ 18 
9  IMPLICATIONS FOR MANUFACURING ENGINEERING OF PROJECT / PRODUCT
CHARACTERISTICS CLASSIFICATION AND PART LEVEL ATTRIBUTION................................ 18 
10  DOCUMENTS STORAGE PERIOD................................................................................................. 19 
11  MODIFICATION OF EXISTING DRAWINGS: CONVERSION CRITERIA ...................................... 20 
12  DRAWINGS WITH CHARACTERISTICS CLASSIFICATION ANTECEDENT TO PRESENT
STANDARD ..................................................................................................................................... 20 
13  FILLING KCDS TABLE ON TITLE BLOCK ...................................................................................... 20 

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3 REFERENCES

AIAG Manual SPC

FGA 01930 Legislative constraints – Components subject to legislative constraints and type-
approval
FPW 9.01102 Quality of supplies
FPW.IFP016 Design and Process FMEA (DFMEA – PFMEA)
FPW.IFP057 Traceability
FPW.MAP010 Production process control
FPW.MEL002 Linee guida per la compilazione del Control Plan
FPW.PEN053 Indication of KCDS on drawings
Quality Manual Chapter 7

For report / safety characteristics see:

FGA 9.01120 Control item characteristics - Identification, recording and retention criteria for
inspection documents
FPW 9.01120/09 Purchasing specification of engine components with part level “Safety”

4 ACRONYMS / TERMS
Note about document encoding:
FGA Standards, tables, specifications Fiat Group Automobiles;
FPW Powertrain standard area (the FPW replaced FPT abbreviation, to differentiate the coding
standards powertrain passenger from the industrial powertrain area).

4.1 Acronyms
A.I.A.G. Automotive Industry Action Group
A.R.O. Assembly Run Off
C.P.C. Control Plan Characteristic
D.F.M.E.A. Design Failure Modes Effects Analysis
E.M.S. Evaluation Measurement System
CF Service Classes
K.C.C. Key Control Characteristic
M.E. Manufacturing Engineering
M.R.O. Machine Run Off
P.E. Product Engineering
P.F.M.E.A Process Failure Modes Effects Analysis
P.P.M. Part Per Million
P.Q.C. Product Quality Characteristic
P.Q.C.-S. Safety Product Quality Characteristic
S.P.C. Statistical Process Control
S.Q.E. Supplier Quality Engineer

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4.2 Terms
Project/Product Characteristics

They are entities specified on a drawing / 3D model with nominal value and tolerance (even unilateral)
measurable and controllable (e.g. diameter, position, thickness, roughness, level of cleanliness, etc…).
A prescription defined only with a minimum value, such as “hardness > 58 HRC”, in order to be
considered a Project /Product characteristic, and then classifiable, must be accompanied by additional
requirements that bind the maximum value. Recalling the previous example, hardening depth should be
introduced, for instance from 0.5 to 0.7 mm (one item with a too high surface hardness compared to the
requested does not fall within the prescribed limits for the depth).

Process parameters

Process parameters are characteristics or physical quantities whose setting and control impact on the
achievement and maintenance of the characteristics of the project.
For instance, pressure, temperature, humidity of ovens/warehouses , chemical and physical
characteristics of a detergent solution, etc...

Type of characteristic depending on the measurability

Project characteristics can be defined by:

 variables: measurable characteristic, expressed as a numerical value and unit of measure;
 attributes: characteristic evaluated either in terms of complies/does not comply, or with other
scales qualitative (e.g. aesthetics).

5 PRODUCTION PROCESS VARIABILITY

Unless otherwise specified, it is assumed that the characteristic under examination is Gaussian
distributed.
The Process Capability is the reference indicator (refer to AIAG SPC Handbook).
Tolerances must be defined in such a way that their variability within the prescribed values does not affect
the function and / or safety of the component, while maintaining a favorable costs/benefits ratio.

Remind that, because of the Gaussian properties, process with a normal distribution and Cp = Cpk = 1
produces statistically 2700 ppm out of tolerance, while a process with Cp and Cpk = 1.33 produces
statistically 63.4 ppm out of tolerance:

Range of tolerances specified in

Out-of-tolerance, parts per
terms of process standard cp million
deviation: Tpre
+/- 3  1 2700 ppm
+/- 4  1,33 63.4 ppm
+/- 4,5  1,5 6.8 ppm
+/- 5  1,67 0.574 ppm
+/- 5,5  1,83 0.038 ppm
+/- 6  2 0.00198 ppm

Table 1 – Number of not compliance pieces

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Example: nominal dimension 10 mm, prescribed tolerance ± 0.1 mm

Cp=Cpk=1 Cp=Cpk=1.33

Li Ls Li Ls
2700
2700ppm
ppm 63 ppm

Xm-3s Xm+3s Xm-3s Xm=10 Xm+3s

Tnat
Tnat
Tpre = 0,2 Tpre = 0,2

Figure 1 – Prescribed tolerance and natural tolerance

Process variability
Loss Function (system response to
the variability of the characteristic
under exam, in terms of loss of
functionality)


Upper tolerance limit

Figure 2 – Loss function

6 GUIDELINE FOR DESIGN CHARACTERISTICS CLASSIFICATION

6.1 Tools
Tools that drive Design to determine the classification of design features of a component are:
 DFMEA;
 Design Standards;

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 Product Specifications, design specifications, customer specifications (e.g. 9.01120 FGA, FGA 1930,
etc, containing information on safety and legislation/approval characteristics);
 Drawings;
 Calculations /Studies (DMU, FEM, gear sizing, WCA, ...).

6.2 Project characteristics classification definition

The classification includes four typologies; in order of importance:

PQC-S = Product Quality Characteristic Safety

PQC = Product Quality Characteristic
CPC = Control Plan Characteristic
STD = Standard

The first three are marked with a special symbol (see FPW.PEN053), to be indicated in the drawing.

 Using the symbol "PQC-S" and "PQC" the Designer requires that the process capability, when
required, is superior to that of the characteristics classified as "Standard" (see tables chap. 7).
Therefore, the probability to produce features out of tolerance is statistically very low.
 Using the symbol "CPC" the Designer, for the same target capability, requires to perform more severe
dimensional controls than a standard feature.

6.3 Definition of characteristics impact

The impact of characteristic is defined as the loss of functionality that occurs when the characteristic
under exam diverges from the value indicated on drawing (nominal + tolerance).

Three levels of impact are defined:

Level Symbol Definition

Highly affects the function:
HIGH A deviation from drawing specification can result in a strong degradation and,
as a limit condition, can lead to loss of function.
Affects the function:
MEDIUM M deviation from drawing specification can result in a slight degradation,
without loss of function.
Minimally affects the function:
LOW B deviation from drawing specification can result in a minimum or no
degradation of function.

Table 2 – Impact definition

The loss of functionality can be represented by a curve or by discrete point values, depending on
theoretical studies (WCA statistics, FEM,…) and/or the available know-how (according to design
standards, carry over, return from the field, experimental tests).

We emphasizes that impact evaluation depends on the specified tolerance range, even for the same
characteristic.
For instance, consider a flange with a flat seal, which ensures the correct sealing.

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It is not appropriate to assess the impact of flatness as “high” in every case. If the flatness value is very
precise (e.g. 0,05 mm – robust design) and far from the limit imposed by the gasket adopted (e.g. 0,2
mm), the impact can be assessed as “LOW”. On the contrary, if the flatness value is close to the limit
imposed by the gasket, the impact has to be assessed as “HIGH”.

6.4 Methodology for design characteristics classification

The following steps ensure a correct and objectified classification:
 functional analysis of the system, from the function expected by the customer, to the technical
elementary function;
 evaluation of effect severity perceived by customer in case of loss of function (see FPW.PEN016);
 failure mode root causes identification;
 correlation of root causes to design specifications;
 evaluation of characteristic impact on the function under exam;
 definition of the classification according to the following tables.

Impact
A M B
10 PQC-S PQC Standard
severity
Effect

8÷9 PQC CPC Standard

6÷7 CPC Standard Standard
1÷5 Standard Standard Standard

Table 3 – Design characteristics classification

Impact
A M B
PQC-S PQC CPC
10 ==> ==> ==>
Class A Class A Class B
Effect severity

PQC CPC CPC

8÷9 ==> ==> ==>
Class A Class B Class B
CPC CPC CPC
6÷7 ==> ==> ==>
Class B Class B Class B
CPC STD STD
1÷5 ==> ==> ==>
Class B Class C Class C

Table 4 – Tightening torque classification (valid for FGA mechanical plants)

For body shop plants and for the suppliers, there is no link between classification and tightening class.
Therefore, the reference is Table 3 “Design characteristics classification”.

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The decision to link the classification of the design characteristic to effect severity and to loss of function
allows to focus investments where a higher degree of customer dissatisfaction or safety/compliance
issues are relevant.
In fact, in correspondence to a sharp loss of functionality that does not imply, however, customer
dissatisfaction (e.g. aesthetic of a not visible part) a “standard” classification is sufficient, whereas a slight
loss of functionality, that implies customer dissatisfaction, requires a more severe classification.
Some examples are shown below (the yellow area is the area under the loss function curve).

Minimum degradation of the function

Figure 3 – Severity 8, Impact B  STD classification

Slight degradation of the function

Figure 4 – Severity 8, Impact M  CPC classification

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Strong degradation of the function

(the function should be nullified)

Figure 5 – Severity 8, Impact A  PQC classification (scrap reduction)

Either the stability of the process or the non-controllability of a characteristic must not have any influence
on the characteristics classification.

In order to comply with the design characteristics, particularly PQCs and CPCs (set by Product Design),
the Process Design is in charge to identify the critical process parameters (also called KCC).
KCCs are not shown on drawing; they are defined during PFMEA phase. An evidence and correlation
with KCCs must be found within the process documentation (Control plans).
KCC management entails a greater attention. For this reason, a registration (or tracking) form, either by
variables or by attributes, is needed.

6.5 Special case

Is highlighted as special case:

 the severity was evaluated 10;

 the impact on the function is medium in the range that goes from the prescribed tolerance Tpre to
Tpre + s; in this range, the effect created by the loss of functionality is serious but not safety
relevant;
 only when the deviation exceeds Tpre + s, the impact becomes high and you have a strong
deterioration of the function, with security implications.

Consider for example the functionality "Ensuring the seal" (see the case illustrated graphically below, in
which the Gaussian distribution of values is dotted while the loss function is represented by a blue line).
For variances content you have a loss of oil without the risk of fire; exceeded the value Tpre + s the oil
leak is likely to cause a fire hazard.

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Figure 6 – Effect: fire risk, Severity 10, Impact M  PQC classification

The Gaussian distribution of the characteristic ensure that no scrap occur beyond the value Tpres
(red area). The range Tpre ÷ Tpre + s (yellow area) include substantially all the scraps. Within this
range, the loss of functionality will generate an effect of lower severity.

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7 MATCHING BETWEEN DESIGN CHARACTERISTICS CLASSIFICATION AND

CAPABILITY TARGET

For matching refer to the three tables below:

Machine
PPAP
Symbol Acceptance Current Production
Requirement
ARO / MRO

PQC-S
Pp ≥ 2 Pp ≥ 2
Ppk ≥ 1.83 Ppk ≥ 1.83 Cpk ≥ 1.67
Part Level S

Pp ≥ 2 Pp ≥ 1.67
PQC Cpk ≥ 1.33
Ppk ≥ 1.67 Ppk ≥ 1.5

Pp ≥ 1.67 Pp ≥ 1.33
CPC Cpk ≥ 1
Ppk ≥ 1.33 Ppk ≥ 1.33

Standard Pp ≥ 1.67
Within tolerance Within tolerance
(no symbol) Ppk ≥ 1.33

Table 5 - Overall

Machine
PPAP
Symbol Acceptance Current Production
Requirement
ARO / MRO

PQC o PQC-S Ppk ≥ 1 Ppk ≥ 1 Cpk ≥ 1

CPC
Ppk ≥ 1 Ppk ≥ 1 Within tolerance

Standard
Ppk ≥ 1 Within tolerance Within tolerance
(no symbol)

Table 6 – For roughnesses

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Machine
Phase / PPAP Current
Symbol Acceptance
Operation Requirement Production
ARO / MRO

At control Ppk ≥ 1 Ppk ≥ 1 Cpk ≥ 1

PQC or PQC-S
(Class A)
Pp ≥ 2 Pp ≥ 1.67
At tightening Cpk ≥ 1.67
Ppk ≥ 1.67 Ppk ≥ 1.5

At control Ppk ≥ 1 Ppk ≥ 1 Cpk ≥ 1

CPC
(Class B)
Pp ≥ 1.67 Pp ≥ 1.33
At tightening Cpk ≥ 1.33
Ppk ≥ 1.33 Ppk ≥ 1.33

Table 7 - For tightening torques (applies only to mechanical assembly plants)

Make parts:

 If alarm limits (set in SPC control charts) are exceeded, refer to the SPC AIAG Manual;
 for PQC and CPC characteristics: handle capability processing according to FPW.MAP010
procedure;
 in general, for all characteristics: control frequencies are governed by guidelines FPW.MEL002.

Buy parts:

 If alarm limits (set in SPC control charts) are exceeded, refer to the SPC AIAG Manual;
 for PQC and CPC characteristics: handle capability processing according to supplier internal
procedures (comply with ISO TS and shared with SQE) or according to FPW.MAP010
procedure;
 in general, for all characteristics: control frequencies must be shared with SQE.

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7.1 Management of PQC-S, PQC and CPC not subject to requirements in terms of
capability

The non-controllability (control feasibility) of a characteristic not preclude its classification (as PQC-S,
PQC, CPC, or Standard).
In cases of:
o destructive controls;
o measurement execution not possible without destructive controls, due to not possible access
(e.g. squareness of cylinder head injector support plan like in FP Diesel 4V engine);
o high measurement execution times (longer than 1 hour for single characteristic).

periodic capability processing is not required; in these cases must be prescribed on the Control Plan:
o direct control on product, with a frequency coherent with the particular type of control, and
recording on the appropriate form;
o indirect control over the process, via "KCC", defining frequency and x-r control chart, or eventual
100% control, and recording on the appropriate form.

The following table describes how to check characteristics with special conditions, with constraint "PQC-
S", "CIP" or "CPC", not subject to requirements in terms of capability.

CURRENT
PRODUCT/PROCESS ARO / MRO / EMS PPAP KCC
PRODUCTION
Heat treatments 10 pieces measured 1 piece for heat Product: Furnace/heater
(Surface hardness and comply with measured comply with control at the temperature
core hardness, drawings/specifications specifications frequency set Gas humidity
hardening depth, (see Control level
structure and position) (simulated, also not Plan) Gas
definitive) Process: composition and
100% KCC regulation
control Hardening oil
temperature
Methane and
ammonia flow
rate
Shot peening 5 pieces measured 1 piece at the start of Product: Shot peening
comply with batch and 1 piece at weekly control intensity (Almen
drawings/specifications the end of batch with degree)
measured comply with diffractometer
(for methodology see specifications Process: Coverage %
M.R.O) KCC daily control

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CURRENT
PRODUCT/PROCESS ARO / MRO / EMS PPAP KCC
PRODUCTION
Welding 5 pieces measured 1 piece at the start of Product: Machine
comply with batch and 1 piece at 100% ultrasonic parameters
drawings/specifications the end of batch inspection and/or control to be
measured comply with daily inspection defined in
(for methodology see specifications on pieces PFMEA
M.R.O) according to
Control Plan

Process:
100% KCC
control if
impossible to
execute 100%
ultrasonic
inspection
Cleaning See guideline See guideline Product: Controls at set-
FPW.MAN050 FPW.MAN050 control at the up frequency
frequency set (temperature,
(see Control detergent
Plan) physical and
chemical
control)
Roughness 5 pieces measured 1 piece measured Product: Self-certification
(special cases e.g. comply with comply with control at the tool control
injector housing plan not drawings/specifications drawings/specifications frequency set
accessible, cylinder (see Control
liners Rwk and Rpk) Plan)
Angles /dimensions Pp on 50 pieces Pp on 50 pieces Product: Self-certification
If required to use control at the tool control
complex equipment such frequency set
as profilometer or (see Control
roundness tester Plan)
(valves seat angle, Process:
screw-crown chamfer self-certification
angle) tool control
Drivings Cg and Cgk ≥ 1,33 1 piece at the start of Product: Control with
1A type test batch and 1 piece at control at the special
the end of batch frequency set equipments of
30 measurements measured comply with (see Control load and stroke.
with Master load cell specifications Plan) (if PQC:
stroke/load;
If CPC: load)
Material integrity Equipment Automatic 100% Product: Machine
acceptance: pieces test with automatic 100% parameters
MAKE Components control according to specific equipment pieces test with control to be
EMS and automatic specific defined in
100% pieces test equipment PFMEA

Material integrity and - See external PPAP Product: To be specified

compliance (Chemical See supplier on Control Plan
analysis, tensile test, Control Plan,
etc.) shared with SQE
BUY Components

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CURRENT
PRODUCT/PROCESS ARO / MRO / EMS PPAP KCC
PRODUCTION
Load or torque - See external PPAP Product: To be specified
breaking, coating See supplier on Control Plan
adhesion, tooth tear Control Plan,
resistance shared with SQE
BUY Components

Table 8 - Correlation Table between PQC-S, PQC, and CPC characteristics with special conditions
not subject to requirements in terms of capability

Note: additional cases must be discussed during Simultaneous Engineering and, if approved, have to
be included in the table above.
For Suppliers exceptions will be shared with SQE during Control Plan approval phase.

7.2 Management of not machined dimensions, related to critical or important

characteristics
Information on not machined critical characteristics (tolerances, materials, critical areas) must be
indicated by P.E. in a table of finished piece drafting.
M.E. will have the responsibility of checking that such information are transferred in a table of raw drafting
piece. In case of discrepancies will prevail a table of finished piece P.E. drafting, which must always be
recalled by table of raw piece drafting.
The achievement of the characteristics in question is not responsibility of ME or plant, but is under the
responsibility of the Supplier.

7.3 Note about material for buy item

Material is self-certified by the Supplier, therefore alloy check is under the responsibility of the same and
data must be stored for 15 years in case of PQC characteristic with part level S.

All components that have PQC classification with part level S on material (chemical composition,
hardness, micrographic test, etc..) must have a marking that identifies the batch of fusion or allow casting
temporal traceability or an equivalent system. The components will be classified part level "T",
Traceability and "S", Safety.

7.4 Management of project critical characteristics in assembly processes

7.4.1 Tightening torques for mechanical plants (see par. 6.4, table 4)
 Tightening torques classified PQC and / or PQC-S belong to class A. These tightening must be
done through the use of electric screwdrivers and / or electronic dynamometric wrenches with
torque / angle control. It must always be possible to determine tightening torque values to
generate the SPC through manual or automatic tools;
 Tightening torques classified CPC belong to class B. These tightening must be done through the
use of electric screwdrivers with torque control, pneumatic screwdrivers with electronic control and
pneumatic screwdrivers with the aid of dynamometric wrenches subject to periodic calibration.
Must be performed a semiannual statistical processing on product, through manual or automatic
SPC.
 Tightening torques classified standard belong to class C. These tightening must be done through
the use of screwdrivers or dynamometric wrenches subject to periodic calibration.

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For classes "A" and "B" is required characteristics management and statistical processing of the same as
described in initial part of chapter 7.

For classes "B" and "C" it’s enough the indication of nominal value and tightening class on manufacturing
standard or, if present, on the assembly drawing.

For class "A" classified PQC, it’s enough the indication of nominal value and tightening class on
manufacturing standard or, if present, on the assembly drawing.

Instead, for class "A" classified PQC-S, is mandatory the indication PQC-S on manufacturing standard or,
if present, on the assembly drawing.

7.4.2 Clearances, alignment, seal couplings

See Functional Check in chapter 8.

8 GUIDELINE FOR COMPONENTS CLASSIFICATION (PART LEVEL)

In addition to the Design Characteristics classification, another classification, regarding the component, is
provided. This additional classification is called “Part Level”.

8.1 Tools
Tools that drive the Design to determine component Part Level classification are:
 DFMEA;
 Engine components safety characteristics: FPW 9.01120/09;
 Design Standards;
 Product Specifications, Design Specifications, customer specifications (e.g. FGA 9.01120, FGA
1930, etc, containing information on safety and legislation/type approval characteristics);
 Existing drawings (of similar components, carry over solutions).

8.2 Component classification (part level)

The following 5 typologies are defined:
 Safety;
 Compliance;
 Functional Check;
 Traceability;
 Component Handling.

Part level typologies must be contained within “KCDS Part level requirement /Functional Checks” field of
the element drawing Title Block.

 Safety (S)
This part level is applicable to engine or transmission components whose failures could affect safety and
basing on this at least a PQC-S or a Functional check related with safety is prescribed.
This is the equivalent of CF1D "service class" of FGA. For details, see section "Links to Servicel Classes
(CF)".

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With regard to the engine, a consolidated list of safety components is defined into the specification
FPW9.01120/09.

If, as output of a DFMEA performed on a component not yet included into the specification
FPW9.01120/09 it is considered necessary to classify on or more characteristics as PQC-S or to
prescribe a Functional check related with safety, the component will be automatically classified with Part
Level “Safety” and service class CF1D and it will be necessary, once the application is consolidated, and
to proceed with the update of the specification FPW 9.01120/09 including it as part of the list.

 Compliance (C)
Can be applied to components having one or more dimensions that, if modified, require a new type
approval of the engine/transmission.
It replaces the FGA characteristics labeled with
The indication of a C in the technical documentation does not necessarily imply an additional control.
For details, refer to the FPW.PEN053 Standard.

 Functional Checks (F/C)

Both functional and performance tests of components/assemblies (e.g. sealing test, rolling test, axial
clearance test, cold test with benches, etc…) to be performed at 100%, are classified as F/C.

By exception, even the characteristics defined by attributes that have to be guaranteed at 100% are
classified as F/C. Examples: presence/absence of a divider baffle, presence/absence of a specific hole,
orientation of a clamp (above or below).
In this case, the Designer requires either a 100% check or an error proof process.
For details, refer to the FPW.PEN053 Standard.

Conditions and objectives of functional tests (including tolerances) will be described on the drawing.
Alternatively, reference to a certain specification is required.

Regarding the clearances tests, it is possible to indicate only the minimum/maximum value, without
tolerance (e.g. minimum clearance 0.2 mm). in this case, a go/no go 100% test is required.

Note: in some particular cases it is allowed to prescribe functional checks not at 100% (e.g. hot test,
destructive controls such as sliding load resistance test, .....).

 Product Traceability (T)

To be adopted for components for which traceability is required and then recording at the plant and
consequent association with its parent group (engine, transmission).
For details about traceability, refer to FPW. IFP057 Procedure.

Note: in some cases, barcode is used only to identify the component (e.g. to avoid assembly errors) but
it does not ensure traceability. Therefore, in these cases, Part Level is not “T”.

 Component Handling (C/H)

For components that require annotations on drawing about:
- particular attentions during transportation (protection elements, shields, maximum inclinations
allowed, storage temperature, etc…);
- precautions to get and maintain the required cleanliness (protective caps, packaging, etc…);
- prescriptions about handling in Plant;
- assembly instructions (e.g. to remove protective caps).

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Classification of a component can exist:

- alone, i.e. no design characteristic is classified as critical. The aim is to define a test/control/data
recording to recommend on the component (e.g. F/C, T) or to highlight a point of attention (e.g. C,
C/H);
- concomitantly with a design characteristic classified as critical. In this case characteristic is
obviously checked according to the rules associated with the classification level determined (CPC,
PQC, PQC-S) but may have additional constraints determined by component classification (e.g. C,
legislative constraints).

8.3 Links with service classes (CF)

A C.F. is essential for products that must meet an General Specifications (e.g. Steel Components –
Specification FGA 9.50206, Iron and Steel Casting - Specification 9.50250, Aluminum and Magnesium
Light Alloy Casting - Specification FGA 9.50305 etc…) when the classes of importance for the quality
characteristics of the product and the limits of acceptability for some defects, defined into the
specification, depend on the Service Class attributed to the product.

There are three types of Service Classes:

CF1 = this class includes components whose loss of function may compromise the safety of the
customer. CF1D is a subclass of CF1 and include components that have part level S;

CF2 = this class includes components whose loss of function has no impact on safety;

CF3 = this class includes components whose loss of function can result in drawbacks of small entities.

Only one correlation can be defined, between the part level "S" and the service class CF1D.

9 IMPLICATIONS FOR MANUFACURING ENGINEERING OF PROJECT /

PRODUCT CHARACTERISTICS CLASSIFICATION AND PART LEVEL
ATTRIBUTION

Investment related to the manufacturing process should be defined according to the importance of the
characteristics and the attribution of Part Level.
Starting from Project/Product characteristics classification and Part Level attribution set by the Designer
(PQC, CPC and Part Level), M.E. will draw up PFMEA and Control Plan, according to Designer decisions.
In addition, Manufacturing Engineering Dept. have to estimate the amount of investment for machinery
and equipment needed to meet the requirements.

In order to meet the PQC requirements, it is essential to:

 identify critical process parameters linked to the product;
 provide equipment testing of adequate class, to measure the characteristics "by variables";
 request the Supplier to meet quality requirements listed by technical specifications (MRO – ARO
– EMS);
 continuously monitor the process, according to SPC rules, or data recording, where required;
 prepare both the machinery and its control system for data collection (if the machinery is
automated provide output for statistical analyzer like QS-Stat);

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 monitor the process using registration charts by variables and perform statistical checks as
required by FPW.MAP010.

Note: in case of 100% automated checks (alternative to SPC) during the production phase, alert
thresholds must be set according to AIAG SPC handbook. In this case it is not required to monitor
the process through SPC.

In order to meet the CPC requirements, it is essential to:

 Identify critical process parameters linked to the product;
 provide equipment testing of adequate class, to measure the characteristics "by variables";
 request the Supplier to meet quality requirements listed by technical specifications (MRO – ARO
– EMS);
 monitor the process using registration charts by variables and perform statistical checks as
required by FPW.MAP010.

In order to meet Part Level “T” requirements, refer to FPW.IFL057 guideline.

To meet the requirements of Part Level "S" consider (see section 8.2) that there are two different
scenarios:

1) the component is Safety because it has at least one characteristic ranked as PQC-S;
2) the component is Safety because at least one F/C Safety relevant is required;

In case 1, to meet the requirements of Part Level Safety it is necessary to guarantee the capability target
specified in Section 7 of this Standard (excluding the special cases of table 8) and to guarantee the
record of the controls/measurements carried out according to FGA 9.01120.

In case 2, it will be necessary to perform the F/C according to the defined prescriptions and record the
results according to FGA 9.01120.
For all the F/C Safety not included into the FPW9.01120/09, specify on drawing the reference to FGA
9.01120 for controls recording and storage.

In order to meet Part Level “C” requirements, see classification rule linked to the characteristic for which
the component is classified as part level C.
As regards Technical Data (Summary data) that determine the "C", checks are to be performed only if
combined with a F/C. Otherwise "C" means that before to modify the data, the Design Dept. must consult
the Homologation Department.

In order to meet Part Level “F/C” requirements, provide a 100% check (or with a specified frequency), or
an error proof process system.

In order to meet the Part Level “C/H” requirements, provide specific packaging and protective devices,
for components with ducts, pipes, union pipes, etc…(e.g. protective caps).

10 DOCUMENTS STORAGE PERIOD

For external FP suppliers, refer to FPW9.01102 “Quality of supplies”.
For FP plants, refer to FPW.MAP010 “Production process control”.

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11 MODIFICATION OF EXISTING DRAWINGS: CONVERSION CRITERIA

Drawing modifications, in order to update critical design characteristic indications, shall not be automatic,
but need to be agreed with Manufacturing Engineering and Quality Departments.

FGA
FP
FGA 9.01120, FGA 01930
FPW.IFN053
FGA 25100/00

Name Symbol Name Symbol

Part level C component

TYPE + indication of involved characteristic in
APPROVAL "rational" field KCDS table, by side of
“Compliance” field
Safety:
PQC-S
REPORT Safety
or
F/C
CRITICAL
H PQC , CPC or
Customer’s point
Standard
of view

not classified (no symbol) Standard or CPC

The decision on the new classification will be taken by the Project Team, taking into account of what is
stated in Chapter 6, involving Quality Department and Manufacturing Engineering Department.

Capability values are those of the " originally standard" recalled CPC / PQC table.

12 DRAWINGS WITH CHARACTERISTICS CLASSIFICATION ANTECEDENT TO

PRESENT STANDARD
If there are drawings containing outdated classification symbols, to be modified:
 drawings will be delivered in line with guidance provided by the present Standard;
 if the drawing code does not change, the conversion of all characteristics classification must be
reported (field “modification” of the drawing);
 conversion must be reported to CRF (if applicable) and then included within ODM, in order to
allow Manufacturing and Cost Engineering to evaluate effects of conversion.

13 FILLING KCDS TABLE ON TITLE BLOCK

Refer to FPW.PEN053 Standard.

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