QUALITY STANDARD May 2012

Initial samples
Q10.09012-4503
for release of the delivery
MDT-AUG / EQS of technical products Page 1 of 15

Contents

1 Field of application and purpose .....................................................................................2

No part of this document may be passed to third parties, reproduced, utilized
or its contents disclosed without the permission of MAN Diesel & Turbo SE.

2 Assessment of manufacturability (Feasibility study) .......................................................2

3 Products which are subject to initial samples ..................................................................3
3.1 Cast and forged blanks ..........................................................................................3
3.2 Machined components, subassemblies and function units ....................................3
4 Initial samples process....................................................................................................3
4.1 Initial sample manufacturing ...................................................................................3
4.2 Initial samples delivery ...........................................................................................4
4.3 Initial sample test report .........................................................................................4
4.4 Initial sample release ..............................................................................................5
4.5 Re-sampling ...........................................................................................................5
4.6 Sampling of alterations ...........................................................................................5
4.7 Cover sheet sampling .............................................................................................6
5 Appendices .....................................................................................................................6
6 Table of changes ..........................................................................................................15
Modifications: See edge marking I

Modified: Checked: Approved

MAN Diesel & Turbo SE
Augsburg Augustin, EQS3 EQS Dr. Zeppenfeld, EQ
Bergmann, EQS1 EQS1

Date of print: 25.08.2021 There is no updating service for the printed version!
 Page 2 of 15
May 2012 / Q10.09012-4503

1 Field of application and purpose

This Quality Standard is valid for the release of the delivery of technical products, which
are produced for the first time by suppliers in accordance with MAN-Diesel & Turbo
specifications or are purchased by MAN-Diesel & Turbo as foreign parts for the first time.
Furthermore this guideline applies in case of process modifications.
Initial samples are considered as samples of semi-finished products, components,
subassemblies or devices, which are exclusively produced with materials, processes,
devices and ambient conditions provided for the future serial delivery.
The documented testing and release of initial samples is the proof that the supplier is
competent to comply with the quality requirements.
If demanded by the order, process capability acc. to quality standard Q10.09012-4504
has to be demonstrated.
This quality standard applies to all parts or components intended for engines or
turbochargers, as well as for propellers and gears produced by MAN-Diesel & Turbo.
Special arrangements contrary to the procedures described in this quality standard are
only admissible after having been confirmed in writing by the responsible quality
assurance department (contact details see FK 0911).

2 Assessment of manufacturability (Feasibility study)

Prior to manufacturing of an initial sample the supplier generally has to make an
assessment of the manufacturability. In this connection following issues have to be
clarified by the production-, quality assurance- and purchase-departments:
 Can the product be manufactured acc. to the functional requirements, drawings
and other specifications?
 Is the required capacity available (machines, workforce for manufacturing and
testing)?
 Can the required quality (dimensional / material) be assured and checked?
 Can the above mentioned items also be assured by involved sub-suppliers?
In case an assessment in writing regarding the manufacturability is required, this will be
noted down in the purchase order of the initial sample. The manufacturability-
assessment has to be sent to MAN-Diesel & Turbo together with the order confirmation.
The documentation has to be done by means of the form FK 0942 (see appendix).

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 3 of 15
May 2012 / Q10.09012-4503

3 Products which are subject to initial samples

3.1 Cast and forged blanks
Prior to starting manufacture with provided, repaired or new patterns and die equipment
respectively, initial samples always have to be presented to the orderer for release.
In case of modification of patterns and die equipment or process modifications
(procedures, devices, relocation), the purchase department of MAN Diesel & Turbo has
to be informed. The responsible quality department decides together with the purchase
department whether new initial samples have to be provided. A delivery of initial
samples has to be ordered explicitly from the supplier by the MAN Diesel & Turbo
purchase department, referring to quality standard Q10.09012-4503.
In respect of cast parts furthermore a solidification-simulation has to be performed by
the supplier, whenever this is required in the initial sample order. In case the simulation
cannot be carried out by the supplier himself, he has to source the solidification-
simulation out to an external service provider.
Should there occur any problems regarding the cast-quality at later serial deliveries, the
supplier has to carry out another solidification-simulation on demand of the orderer.

3.2 Machined components, subassemblies and function units

Regarding machined parts and assemblies acc. to MAN Diesel & Turbo design, initial
samples have to be provided in case the part (code number) never before has been
manufactured by the respective supplier.
Sealing material requires one initial sample for each new material and compound
respectively for production release.
With regard to function units according to manufacturer design, the function
characteristics as well as the installation and connection dimensions are subject to
initial samples.
A delivery of initial samples has to be explicitly ordered at the supplier by the MAN
Diesel & Turbo purchase department, referring to the quality standard Q10.09012-4503.

4 Initial samples process

4.1 Initial sample manufacturing
The purpose of initial samples is to prove the stability and capability of the
manufacturing process for subsequent serial production. For this reason initial samples
have to be manufactured under serial production conditions. This means, that initial
samples have to be produced using the same processes and equipment, which will be
used later for serial production.
Modifications of the manufacturing procedure or relocation to other facilities have to be
considered as process-modifications. All process-modifications have to be reported in
writing to MAN Diesel & Turbo, prior to their introduction. If necessary, a new sampling
inspection has to be carried out.

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 4 of 15
May 2012 / Q10.09012-4503

4.2 Initial samples delivery

Initial samples have to be packed separately for dispatch, to be marked clearly and to be
stated in the dispatch note. Initial samples have to be explicitly delivered “for the
attention of incoming goods inspection”. The assignable initial sample test report has to
be enclosed to the goods.

4.3 Initial sample test report

The supplier has to check all material-, geometry- and function-features for compliance
with the technical specifications stated in the order (drawings, guidelines, standards and
purchase order text) and has to document both the required values and the actual
values in the initial sample test report. In case of changed specifications (e.g. drawing
modifications / new drawing index) or changed production conditions (process
modifications, different manufacturing devices), all features influenced by the changes
have to be documented. For examination of an assembly (function unit) all single part
drawings and the assembly drawing have to be numbered and examined.
For the initial sample documentation the following documents have to be used
(templates see appendices, chapter 5):
a) Completed cover FK 0915
b) Completed form FK 0916 for documentation of inspection- and measuring results.
Alternatively documentation using VDA-templates is accepted. The item numbers
in form FK 0916/test sheet have to coincide with the item numbers in the
numbered drawing. The specified values have to be stated including respective
tolerances (also general tolerances).
c) Acceptance certificate 3.1 acc. to DIN EN 10204, including results of the chemical
analysis and material properties acc. to MAN-material specification. Special
requirements, stated in the order text concerning initial sampling of materials,
apply additionally. In case the material used is internal supplier development and
not acc. to MAN-material specification or any valid standard, a material sheet has
to be included.
d) Numbered MAN-drawing (all dimensions and drawing specifications (e.g. surface
roughness, hardness values, reference dimensions, test pressures, markings
etc.) have to be numbered and included in form FK 0916. Only MAN-drawings are
accepted.)
e) FQP (forward quality plan / control plan) acc. to FK 0940 depicts the features
(material, dimensions, marking etc.), which will be inspected during serial
production, the measuring device to be used, the number of measurements and
the scope of end-of-line-inspection. *
f) Deviations have to be indicated in advance by form FK 0904 “concession
application” and be approved by the responsible quality department. The signed
concession application has to be enclosed to the initial sample documentation.
g) If specified in the order text, an assessment of manufacturability (feasibility study)
has to be enclosed.
h) Documentation including the results of the solidification-simulation of cast-parts, if
required in the order

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 5 of 15
May 2012 / Q10.09012-4503

i) If required, CE-documentation (declaration of conformity, declaration of

incorporation, instruction manual, installation instruction etc.)
* For these documents also a layout deviating from the templates may be used.

4.4 Initial sample release

The incoming goods inspection department of MAN Diesel & Turbo carries out a counter
check and, if required, further checks in order to evaluate the initial samples presented.
The scope of testing will be defined at the discretion of MAN-Diesel & Turbo.
The quality assurance department for purchased parts is responsible for the release of
initial samples of engine and turbocharger parts.
Initial samples are released on condition that the features found are in accordance with
the technical specifications referred to in the order. Initial samples, which differ from the
specification, seem, however, to be usable, can only be released under reserve or under
special conditions.
If the parts are not released, initial samples have to be presented again after correction
of manufacture or a modification of the technical specification has to be applied for by
the supplier at the responsible purchasing agent of the orderer. The supplier will be
charged with the costs of another initial sampling.
The release of initial samples by the orderer does not at all relieve the supplier from his
full responsibility for strictly manufacturing of the initial samples and subsequent serial
deliveries acc. to the specifications.
The supplier will be informed in writing by MAN-Diesel & Turbo about the decision
regarding the initial sample. Without initial sample release in writing or any special
agreement for release, issued by MAN Diesel & Turbo, the supplier is not authorized to
effect further deliveries referring to this code number.

4.5 Re-sampling
In case an initial sample is rejected, another complete initial sampling, including
documentation acc. to section 4.3, must be carried out.
Additionally the cover (FK 0915) of the previous initial sampling, reviewed by MAN
Diesel & Turbo, has to be enclosed.

4.6 Sampling of alterations

Sampling of alterations is carried out only for evaluation of alterations effected to parts
already released. In this connection only modified dimensions and specifications are
numbered in the MAN-drawing and entered in the dimension record (FK 0916). In the
field “remark (supplier)” of the initial sample cover sheet FK 0915, the supplier has to
register, that a sampling of alterations is concerned. Sampling of alterations will be
explicitly ordered by the purchase department of MAN Diesel & Turbo. For this purpose
the original manufacturing process has to be adhered to.

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 6 of 15
May 2012 / Q10.09012-4503

4.7 Cover sheet sampling

Cover sheet sampling is applied to assembly code numbers, whose single parts are
already released using other code numbers, in order to sample and release the
assembly. In that case only a FK 0915 cover sheet is required. The supplier has to enter
the code numbers already sampled and released in the field “remark (supplier)”. Cover
sheet sampling will be explicitly ordered by the purchase department of MAN Diesel &
Turbo.

5 Appendices
The actual templates each of following forms have to be used:
a) FK 0915
b) FK 0916
c) Acceptance certificate 3.1 (example)
d) Numbered MAN-drawing (example)
e) FQP (forward quality plan - example)
f) FK 0904 concession application
g) FK 0942 Feasibility study

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 7 of 15
May 2012 / Q10.09012-4503

a) FK 0915

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 8 of 15
May 2012 / Q10.09012-4503

b) FK 0916

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 9 of 15
May 2012 / Q10.09012-4503

c) Acceptance certificate 3.1 (example)

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 10 of 15
May 2012 / Q10.09012-4503

d) Numbered MAN-drawing (example)

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 11 of 15
May 2012 / Q10.09012-4503
e) FQP (example)

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 12 of 15
May 2012 / Q10.09012-4503

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 13 of 15
May 2012 / Q10.09012-4503

f) FK 0904 Concession Application

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 14 of 15
May 2012 / Q10.09012-4503

g) FK 0942 Feasibility Study

FK 0942

Print date: 25.08.21 There is no updating service for the printed version!!
 Page 15 of 15
May 2012 / Q10.09012-4503

6 Table of changes

Initiator
04 / 2010 Text supplementation EQS
05 / 2012 Text supplementation EQS

Changes in the current issue compared to the last issue

Current issue: May 2012

Last issue: April 2010

The contents of this quality standard have been supplemented by some text passages.
Changes in the guideline are each marked with black lines at the right edge of the text!

Print date: 25.08.21 There is no updating service for the printed version!!