Corporate Standard

Marking of Special Characteristics and

HELLA Norm
Inspection Characteristics
HN20037
and Verification Requirements

Contents
1 Process assignment acc. to HPH ....................................................................................................... 1
Its contents are not to be passed on, duplicated, exploited or disclosed without our express permission. All rights reserved, especially the right to apply for protective rights.

2 Purpose and scope .............................................................................................................................. 1

3 Level of confidentiality ........................................................................................................................ 2
4 Normative references .......................................................................................................................... 2
5 Definitions and abbreviations ............................................................................................................ 2
5.1 Special Characteristics ................................................................................................................... 2
5.1.1 Special Characteristics related to Safety (SC/S) ................................................................................ 3
5.1.2 Special Characteristics related to legal and regulatory Requirements (SC/L) .................................... 3
5.1.3 Special Characteristics related to Functions and Requirements (SC/F) ............................................ 3
5.2 Inspection Characteristics (IC) ........................................................................................................ 3
5.3 Examples of Special Characteristics and Inspection Characteristics ............................................. 3
5.4 Further definitions or terms relating to dimensions and characteristics.......................................... 4
6 Marking of Inspection and Special Characteristics in Technical Product and Process
Documentation ..................................................................................................................................... 4
6.1 Marking according to customer specification (at HELLA) ............................................................... 4
This document has to be treated confidentially.

6.2 HELLA Marking ............................................................................................................................... 4

6.2.1 Inspection Characteristics ................................................................................................................... 4
6.2.2 Special Characteristics ........................................................................................................................ 5
6.2.3 Total Number of Inspection and Special Characteristics on the Drawing ........................................... 5
6.3 Verification Requirements ............................................................................................................... 6
6.3.1 Verification Requirements for Inspection and Special Characteristics ............................................... 6
6.3.2 Definition of Inspection Level .............................................................................................................. 6
6.3.3 Complementary Requalification Requirements for HELLA Suppliers ................................................. 9
7 Changes made since the previous edition........................................................................................ 9

1 Process assignment acc. to HPH

Business process: BMM-50 Manage Knowledge, Quality, Improvement and Change
Main process: BMM-50-40 Apply General Supporting Quality Methods
Sub-process: BMM-50-40-70 Identify and Control Special Characteristics and Inspection
Characteristics

2 Purpose and scope

The determination of Inspection and Special Characteristics and their tolerances is one of the essential
prerequisites to secure the product and process quality. This norm describes the uniform marking of
Inspection and Special Characteristics within the HELLA group. Furthermore, the norm defines which
verification requirements apply within the HELLA group as well as for HELLA suppliers.
This norm applies to HELLA and all HELLA group companies, as well as affiliated companies with company
management by HELLA. This norm shall also be applied by all service providers/suppliers assigned by
HELLA.

Note:
HF-00128 (2018-06-25)

For tolerancing please refer to HN22024.

At HELLA Special Characteristics are determined according to BMM-50-40-70 and must be marked
consistently in all product and process documents as far as they are included in these.

Edition date: Designer of the HN: PDE of the related process: PLD of the related process:

2021-06-01 E-QD-B Norbert Kröger E-QD-B Norbert Kröger E-QS Dr. Tobias Becker
Replacing: HN20037 Edition: 2015-07-27 Pages: 9 Page: 1
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3 Level of confidentiality
This HELLA Norm is assessed as INTERNAL.
It is available for HELLA suppliers.

4 Normative references
The integration of Inspection and Special Characteristics in the drawing shall be executed according to
function-, production- and inspection-related aspects.
Herein, external requirements by bodies, public authorities and customers as well as HELLA-internal
requirements must be considered and may have to be agreed with the customer and supplier.
The following references apply to the current issue of each document, unless otherwise agreed.
ISO 286-1
Geometrical product specifications (GPS) - ISO code system for tolerances on linear sizes - Part 1: Basis of
tolerances, deviations and fits (ISO 286-1:2010)
ISO 128-1 Technical drawings — General principles of presentation (ISO 128-1:2003)
ISO 1101
Geometrical Product Specifications (GPS) - Geometrical tolerancing - Tolerances of form, orientation,
location and run-out (ISO 1101:2017)
HN22024
Technical product specification (TPS) – Tolerancing and general tolerances (HELLA-internal norm)
HN22025
Technical product specification (TPS) – Deviations from international standards
HN22026
Technical product specification (TPS) - Execution of component and product measurements
BMM-50-40-70
Identify and Control Special Characteristics and Inspection Characteristics (HELLA-internal process)
HF-00150
List of Special Characteristics (HELLA-internal form)
HN11020
Qualify and Control of Process (HELLA-internal norm)
VDA Joint Quality Management in the Supply Chain
A process description covering Special Characteristics (SC)
VDA Band 1 Documented Information and Retention
Guideline for control and retention of documentation within the framework of the product lifecycle –
particularly their classification
AD-00385 (former HP-C-509)
HELLA Quality Management - Guideline for Suppliers

5 Definitions and abbreviations

5.1 Special Characteristics

Special Characteristics are characteristics, which may have an effect on the safety, the compliance with legal
provisions or homologation, or whose nonfulfillment will endanger fit, function or the further processing of the
product and might lead to severe economic damage (following IATF 16949:2016). Herein, the state-of-the-art
of science and technology must always be considered. Special Characteristics are defined as such
externally (legislation, authorities, customers) or on the basis of internal expertise, standards and risk
assessments.
Special Characteristics must be assured and/or monitored, so that compliance with the requirements is
always ensured. They may relate to the product or to the process. They must be unambiguous and verifiable
either on the product or in the process.

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Special Characteristics must be marked without exception in all technically relevant documents of the
product and process documentation and run like a common thread through product development and
production all the way from the customer requirements to the product manufactured under series conditions.
According to their importance for the product, Special Characteristics are subdivided into the categories
• SC/S – Special Characteristics related to safety
• SC/L – Special Characteristics related to legal and regulatory requirements
• SC/F – Special Characteristics related to functions and requirements.
For all documents that include Special Characteristics the recommendation for retention period of “VDA Joint
Quality Management in the Supply Chain - A process description covering Special Characteristics (SC)” has
to be followed.
Retention period (operating and archiving period):
➢ 30 years for Special Characteristics SC/S and SC/L
➢ 10 years for Special Characteristics SC/F
Besides that, customer specific requirements or higher requirements need to be considered.
In general, the specific requirements of “VDA Band 1 Documented Information and Retention” need to be
considered.

5.1.1 Special Characteristics related to Safety (SC/S)

A Special Characteristic is to be classified as SC/S, when safety aspects (safety requirements, product safety,
safety-relevant consequences) are concerned.
The non-compliance of these characteristics may cause an immediate risk to life and limb.

5.1.2 Special Characteristics related to legal and regulatory Requirements (SC/L)

Special Characteristics related to legal and regulatory requirements refer to specifications valid at the time of
the introduction of the product to the market. These may be legally or approval-relevant (e.g., homologation).

5.1.3 Special Characteristics related to Functions and Requirements (SC/F)

For these characteristics important functional requirements (fit, form, function, performance) could be
affected.

5.2 Inspection Characteristics (IC)

Inspection Characteristics serve primarily to control production processes. They can be defined as
mandatory Inspection Characteristics towards the production areas based on experience and process know-
how. The definition will be done using the respective marking in the drawing (see paragraph 6.2.1). These
Inspection Characteristics must then be included into the Control Plan and have to be marked there
accordingly, too.
Evidences (quality records) for Inspection Characteristics are to be handled and archived according to the
requirements of “VDA Band 1 Documented Information and Retention”.

5.3 Examples of Special Characteristics and Inspection Characteristics

Below you will find several examples of types of characteristics which may be marked as Special or
Inspection Characteristics:
• Overload protection
• Flammability of materials, e.g. acc. to FMVSS 571 §302
• Requirements related to frequency and transmission power
• Density, resilience requirements
• Heat resistance, impact resistance, flexural strength of materials
• Customer interfaces

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• Decorative properties
• Geometry-related dimensions
• Shape and positional tolerances
• Information on toothing, threading etc.
• Information on surface properties
• Information on heat and surface treatment, material and welding, etc.
• Characteristics related to the process, e.g., pull/push/shear forces, starting power

5.4 Further definitions or terms relating to dimensions and characteristics

Further definitions of terms relating to dimensions, tolerances and fits as well as their marking are given in ISO
286-1, ISO 1101 and ISO 128-1.
Variable characteristics are measured and their characteristic values are indicated as numerical values plus
unit (e.g. 0.5 mm, 10 V).
Attributive characteristics may be described with words (e.g., o.k./n.o.k., flammability rating: minimal
hazard/slight hazard/moderate hazard/serious hazard/severe hazard, assessment of the optical quality by
means of school marks: 1 = excellent, …, 6 = very poor).

6 Marking of Inspection and Special Characteristics in Technical Product and Process

Documentation

6.1 Marking according to customer specification (at HELLA)

Special Characteristics must be marked in the entire product and process documentation according to this
HN20037 paragraph 6.2. The assignment of special customer symbols to the HELLA marking is executed,
as far as applicable, by means of an allocation table used by HELLA (part of HF-00150 List of Special
Characteristics). This is also to be applied for module projects (components and documents apply for several
customers).
However, on customer request, the customer symbols can also be integrated in the technically relevant
documents of the product and process documentation to the agreed extent (especially in the customer
drawing). The applicable customer requirements and customer signs for Special Characteristics are to be
established at HELLA for each project.

6.2 HELLA Marking

6.2.1 Inspection Characteristics
Inspection Characteristics will be marked with the following characters:
IC/P Inspection Characteristics for production
The determination of Inspection Characteristics will be done in a drawing with the addition
IC/P Px (Px see 6.3.2)
separated by space characters as the last piece of specification behind the dimension (or other requirements
on the drawing), e.g.:

For automatic scan and interpretation of drawings this order must be followed strictly.
For better visualization in the drawing an upside-down triangle has to be used. It shall be applied near the
characteristic, so that a clear relation is given, the exact position is free to choose.

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As a consequence of this the Inspection Characteristics must be included into the Control Plan and be
marked there accordingly, too. In the Control Plan the Inspection Characteristics will be marked with the
same sequence of characters “IC/P” in the classification column.
A marking of Inspection Characteristics in further documents is not required.

6.2.2 Special Characteristics

Due to their high importance the Special Characteristics must be marked in all relevant documents, as far as
they are included in these. For a clear identification of Special Characteristics the following characters are
used (following VDA):
SC/S Special Characteristics related to safety
SC/L Special Characteristics related to legal and regulatory requirements
SC/F Special Characteristics related to functions and requirements
To find the Special Characteristics more easily in free text documents (e.g., work instructions, test
instructions), it is recommended to highlight these characters in bold and/or in square brackets.
The determination of Special Characteristics in a drawing will be done similar to the Inspection
Characteristics. For the Special Characteristics, too, at the very end of the dimension (or other requirement)
SC/S Px or SC/L Px or SC/F Px (Px see 6.3.2)
must be added, separated by space characters, e.g.:

For automatic scan and interpretation of drawings this order must be followed strictly.
For better visualization in the drawing an upside-down triangle has to be used. However, to highlight the
special importance of the characteristic an additional rectangle will be attached on top to distinguish it from
an Inspection Characteristic. It shall be applied near the characteristic, so that a clear relation is given, the
exact position is free to choose.
Special Characteristics shall be defined unambiguous and therefore multiple dimensions (see following
picture) should be avoided when assigning a Special Characteristic. If it is not possible to avoid it at least it
must be possible to clearly assign test results to each of the individual dimensions.

In case of tolerance frames the assignment of a SC or IC must be done for each characteristic separately at
the right side of the tolerance frame (see following example).

6.2.3 Total Number of Inspection and Special Characteristics on the Drawing

The total number of Inspection and Special Characteristics and the reference to this HELLA Norm is to be
indicated on the drawing as follows (only to be added if at least an IC or SC is existent on the drawing):

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---------------
Special Characteristics and Inspection Characteristics
according to HN20037: 2021-06-01
Total number of Special Characteristics and Inspection Characteristics:
SC/S - (Special Characteristics related to safety) = 0
SC/L - (Special Characteristics related to legal and regulatory requirements) = 0
SC/F - (Special Characteristics related to functions and requirements) = 1
IC/P - (Inspection Characteristics) = 0
---------------

Adjustment of placeholder (numbers) with real number of SC and IC.

The total number contains Special Characteristics and Inspection Characteristics defined on the drawing
(including all sheets).

6.3 Verification Requirements

Fundamentally, each dimension and characteristic given in a drawing must be observed by all parts.

6.3.1 Verification Requirements for Inspection and Special Characteristics

For each Inspection and Special Characteristic, the inspection level is indicated on the drawing (see
paragraph 6.2). The inspection levels and the related minimum requirements are described in paragraph
6.3.2. Details relating to the inspections (extent and frequency of random sampling, reaction plan,
requalification tests) are agreed between the manufacturer and the customer and stated in the Control Plan
(pre-series and series).
The tests according to the Control Plan have to be executed and documented by the manufacturer
throughout the entire series production. The results must be made available on request.
As Special Characteristics as well as Inspection Characteristics play an essential role in ensuring product
and process quality, it must be ensured by means of initial qualification and continuous process monitoring
that the requirements relating to Inspection and Special Characteristics are always fulfilled on all
manufactured parts/devices. The inspection level will be determined in the development team with respect to
technical reasons.

6.3.2 Definition of Inspection Level

Proof of machine and process capability values is executed according to
HELLA-internal procedure according to HN11020 and
Proceeding for external suppliers according to „HELLA Quality Management - Guidelines for Suppliers“.
Divergent requirements of capability indices compared to HELLA standards must be specified clearly (e.g. in
the drawing).

Inspection level P1
Measured variables:
1) Proof of short-term-/machine capability Cmk for ISIR/PSW1
Calculation basis ≥ 50 pcs per tool/nest/cavity.
2) Proof of preliminary process capability Ppk
Calculation basis ≥ 125 pcs, e.g. collected in 25 samples at 5 pcs each.
3) Proof of long-term process capability Cpk or Ppk respectively with instable processes
Calculation basis: production period ≥ 20 days and ≥ 250 pcs (e.g. 2 x 5 parts per shift in 2-shift production:
400 parts after 20 production days; or 1 x 5 per shift in 1-shift production: 250 parts after 50 production
days).

1 Initial Sample and Inspection Report / Part Submission Warrant

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4) The collection of the random samples for preliminary and long-term process capability must be
accompanied by a process control card (SPC-card). It must be maintained over the entire production period.
The test frequency must be selected to ensure a sensible statistical process control suitable for the
production process. Random sampling size is same as defined for 2) and 3).
Re. 1-4: For processes with very small production volumes (e.g., annual requirement produced in < 5 shifts)
or for special processes (e.g., production of sealing rings in a 50-cavity tool), special agreements can be
made between manufacturer and customer.
If short-term capability, preliminary capability or long-term process capability cannot be proven, 100% testing
of the characteristic is required. If 100% testing is planned anyway (e.g. in highly automated lines), process
capability and trends analyses are not mandatory (nevertheless recommended for process improvements).
In case of destructive tests or very complex tests, a suitable random sampling test including control card
monitoring may be executed instead. The actual reaction plan must be described in the Control Plan, in
agreement with the internal customer or HELLA for external suppliers.
Documentation (HELLA-internal: qs-STAT-reports):
Re. 1), 2), 3) Initial:
• Capability indices, distribution, mode of calculation
• Actual value, mean value, standard deviation
Re. 4) Permanent:
• SPC-card

Attributive characteristics:
100% testing must be executed throughout the entire production period.
The documentation/proof of 100% testing (measured variables as well as attributive characteristics) will be
determined project-specifically.

Inspection level P2
1) Proof of short-term/machine capability (Cmk) for ISIR/PSW
Calculation basis ≥ 50 pcs per tool/nest/cavity.
2) Regular random sampling for actual values (frequency depends on the potential changes in the process,
such as material batch changes etc.) with random sample size of typically 3-5 pcs per tool/nest/cavity. For
these characteristics, it is not mandatory to keep a control card.
Documentation (HELLA-internal: qs-STAT-reports):
Re. 1) Initial:
• Capability indices, distribution, mode of calculation
• Actual value, mean value, standard deviation
Re. 2) Permanent:
• Actual values

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Inspection level P3
1) Proof for ISIR/PSW: Actual values lie within the specification. Sample size ≥ 5 pcs per tool/nest/cavity.
2) Regular random sampling for actual values (frequency depends on the potential changes in the process,
such as material batch changes, tool wear depending on the number of shots etc.) with sample size of
typically 3-5 pcs per tool/nest/cavity. For these characteristics, it is not mandatory to keep a control card.
Documentation:
Re. 1) Initial:
• Actual values
Re 2) Permanent:
• Actual values

Inspection level P4
The verification requirements of inspection level P4 correspond to those of P3, but they are used for
attributive characteristics or measured variables which will be tested with a gauge during production.
1) Proof for ISIR/PSW: Actual values lie within the specification. For attributive characteristics a clear
o.k./n.o.k. result is sufficient. Sample size ≥ 5 pcs per tool/nest/cavity.
2) Regular random sampling with an attributive test, e.g. o.k./n.o.k. gauge (frequency depends on the
potential changes in the process, such as material batch changes, tool wear depending on the number of
shots etc.) with sample size of typically 3-5 pcs per tool/nest/cavity.
Documentation:
Re. 1) Initial:
• Actual values (measured variables) or test result o.k./n.o.k. (attributive characteristics)
Re. 2) Permanent:
• Test result o.k./n.o.k.

Inspection level P5
1) Proof for ISIR/PSW: Actual values lie within the specification. For attributive characteristics a clear
o.k./n.o.k. result is sufficient. Sample size ≥ 5 pcs.
Inspection level P5 is applied for all Inspection or Special Characteristics which change very slowly, if at all,
and which do therefore not require series-accompanying monitoring. A deviating random sampling number
can be defined (e.g. in case of high-effort or destructive tests), it does, however, require agreement with the
internal customer or HELLA. P5 characteristics are to be tested 1x per year unless agreed otherwise.
Specific HELLA-internal CoP (Conformity of Production) test frequencies are defined in AD-HN29201-01.
Documentation: Actual values (measured variables) or test result o.k./n.o.k. (attributive characteristics)

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Inspection
P1 P2 P3 P4 P5
level
1.) Short-term/machine
capability Cmk Actual values lie Actual values lie
2.) Preliminary process within the within the
Short-term/machine Actual values lie specification or clear specification or clear
Proof capability Ppk within the
capability Cmk o.k./n.o.k. result (for o.k./n.o.k. result (for
3.) Long-term process specification
attributive attributive
capability Cpk or Ppk for characteristics) characteristics)
instable processes
1.) ≥ 50 pcs per
Initial

tool/nest/cavity
Extent of 2.) ≥ 125 pcs e.g. collected ≥ 50 pcs per ≥ 5 pcs per ≥ 5 pcs per
≥ 5 pcs
sampling in 25 samples, 5 pcs each tool/nest/cavity tool/nest/cavity tool/nest/cavity
3.) Production period
≥ 20 days and ≥ 250 pcs

Capability index, Capability index, Actual values Actual values

distribution, mode of
Documentation calculation, actual values,
mean value, standard
deviation
Keeping of a process
Proof
Permanent
distribution, mode of (measured variables) (measured variables)
calculation, actual Actual values or test result or test result
values, mean value, o.k./n.o.k. (attributive o.k./n.o.k. (attributive
standard deviation characteristics) characteristics)
Regular random Regular random Regular random
Annual testing unless
sampling for actual sampling for actual sampling with an

control card (SPC) otherwise specified

values values attributive test
Extent of typically 3-5 pcs per typically 3-5 pcs per typically 3-5 pcs per
as initial for 2) and 3) ≥ 5 pcs
sampling tool/nest/cavity tool/nest/cavity tool/nest/cavity
Process control card
Documentation Actual values Actual values Test result o.k./n.o.k. Test result o.k./n.o.k.
(SPC)
100% testing is required if A deviating sample
Amendments

one of the capabilities size may be defined,

cannot be proven. but requires agree-
Complementary
ment with the internal
regulations For attributive
customer/HELLA.
characteristics, 100%
HELLA-internal CoP
testing is required
see AD-HN29201-01.
Table 1: Overview – Inspection Levels

6.3.3 Complementary Requalification Requirements for HELLA Suppliers

All characteristics with an inspection level will be part of the regular requalification, which, if not agreed
otherwise, has to be done at least once a year and testing at least 5 parts per tool/nest/cavity. For
characteristics with an inspection level of P1 the proof of long-term process capability (Cpk) is requested –
except for 100 % testing.
For all characteristics which are controlled regularly in series production, requalification must be done always
based on the latest results of these series tests.

7 Changes made since the previous edition

In general, all changes are highlighted with grey in this HELLA norm. Main changes are:
- Chapter 4: References were updated and/or added/removed (mainly in chapter 4 but also
throughout the other chapters if named there)
- Chapter 5.1 and 5.2: Archiving periods and definitions adjusted to current definitions of VDA
standards
- Chapter 6.2: Small adjustments of existing definitions to make definitions unambiguous.
Requirements added for multiple dimensions and tolerance frames.
- Chapter 6.3: Small adjustments of existing definitions to make definitions unambiguous. For some
inspection levels the sample size was changed from “≥ 5 pcs” to “typically 3-5 pcs”.

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