Autoliv Standard

Special Characteristics Classification – AS052

AUTOLIV STANDARD

Special Characteristics Classification

AS052

Distribution to: responsible persons as per Distribution List AS 0-2 – 8-Jun-2016

Author: Werner Wulfers Approved by: Svante Mogefors

Paul Heasman
Version: 5.2 Release date: 9-Jun-2016 Pages: 13

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Autoliv Standard
Special Characteristics Classification – AS052

Table of Contents

AS052

INTRODUCTION ................................................................................................................................................. 3

1 PURPOSE................................................................................................................................................... 3

2 SCOPE........................................................................................................................................................ 3

3 RESPONSIBILITY ...................................................................................................................................... 3

4 DEFINITION ................................................................................................................................................ 4

5 PROCEDURE ............................................................................................................................................. 5
5.1 IDENTIFYING SPECIAL CHARACTERISTICS [CC]/[SC] .......................................................................... 5
5.2 THE [CC]/[SC] LIST .......................................................................................................................... 5
5.3 CONTROLLING [CC]/[SC] .................................................................................................................. 6
5.3.1 During development ....................................................................................................................... 6
5.3.2 During PPAP (Production Part Approval Process) ........................................................................ 6
5.3.3 During serial production ................................................................................................................. 7
5.4 [CC/SC]S LIST DOCUMENT MANAGEMENT ........................................................................................ 8
5.4.1 Language and Access ................................................................................................................... 8
5.4.2 Format for project D & PFMEA ...................................................................................................... 8
5.4.3 Master [CC]/[SC] list ...................................................................................................................... 9
5.4.4 Distribution outside Autoliv............................................................................................................. 9
6 REFERENCES ......................................................................................................................................... 10

7 APPENDICES ........................................................................................................................................... 10
7.1 AS052 APPENDIX A – [CC]/[SC] – SUMMARY ................................................................................. 10
7.2 AS052 APPENDIX B – [CC]/[SC] - LIST ........................................................................................... 10
8 MODIFICATION INDEX ............................................................................................................................ 10

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Autoliv Standard
Special Characteristics Classification – AS052

Introduction
This Autoliv Standard outlines requirements for how to control risks related to
product and process through the identification and management of special product
and process characteristics (named Critical Characteristics and Significant
Characteristics).

1 Purpose
The purpose of this standard is to explain how to manage and control special
product and process characteristics to ensure that both products and processes will
fulfill functional and regulatory requirements.

It explains:
· what are CRITICAL and SIGNIFICANT CHARACTERISTICS, respectively called
[CC] and [SC].
· how to manage [CC] and [SC].during development of product and/or
manufacturing process, and during ongoing production.
· requirements that must be met for [CC] and [SC].during PPAP and production.

2 Scope
The standard is valid for all new designs since date of release of present standard
including Global Development future designs on product road map.
Global Design Authority (GDA) / Design Authority (DA) shall decide on a case to
case basis if this standard shall be applied

· to existing product already defined on road map

or
· to new product and assembly process that previously passed Tollgate 2 of
APDS.

3 Responsibility
At the local Autoliv Company the Engineering Manager / Director (Product and
Process) is responsible for the management of special characteristics during
development process.

After production launch (TG4) (ref. AS100), the Production Manager / Director is
responsible for the management of special characteristics in conjunction with the
related DAs.

The Plant Quality Manager / Director is responsible to ensure that the

requirements defined in this standard are implemented within the local Quality
Management System.
The Purchasing Manager / Director is responsible to communicate and enforce
this standard at the supplier level.

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Autoliv Standard
Special Characteristics Classification – AS052
4 Definition
Characteristic is a dimension or a physical, chemical, electrical, mechanical or
optical property. All characteristics have to be measurable (through variable or
attribute) directly or indirectly.

Attributive characteristics are qualitative data that can be categorized for

recording and analysis, e.g. the presence of a required component, the installation
of all required fasteners.
Other examples are characteristics that are inherently measurable (i.e. could be
treated as variable data), but where the results are recorded in a simple yes/no
option, such as acceptability of a shaft diameter when checked on a go/no-go gage,
or the Flammability, Dynamic Tests acc. ECE R16, Airbag Inflation Tests, etc..

Variable characteristics are quantitative data, where measurements used for

examples include the diameter of bolt in millimeters, the tensile strength of a bracket
in kN, the concentration of electrolyte in percent, or the torque of a fastener in Nm
(Newton-meters).

All products and processes have features described by characteristics that are
important and need to be controlled. However, some characteristics (called Special
Characteristics) require extra attention/efforts to minimize the risk of adverse
consequences.

Special characteristics are [CC] and [SC]. [CC] stands for Critical Characteristic
and [SC] for Significant Characteristic. They are classified according to the effect on
the function of the final product.

[CC] Critical Product / Process characteristic that may affect product safety,
operator safety and/or compliance with regulatory (governmental and legal)
requirements.

[SC] Significant Product / Process characteristic that may affect a product form,
fit or function or has other valid reasons for specific control and documentation.

Ex: dimensions that control features that fit to interface component at customer
should be signified as [SC] (i.e. PAB module to IP, DAB to SW, Anti-rotation tab on
retractor to sheet metal hole, locating holes, etc.).

Symbols for special characteristics (Table 4.1)

These symbols shall be used within Autoliv as a standard.

OEM symbols are only valid for customer drawings.

Correspondence in between Customer and Autoliv symbols and requirements is

managed in a symbols’ reference list (Ref. Special Characteristics Symbols’ list)
stored in Autoliv Quality Information database and linked to the present standard.

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Autoliv Standard
Special Characteristics Classification – AS052

Table 4.1

5 Procedure

5.1 Identifying Special Characteristics [CC]/[SC]

Special Characteristics [CC]/[SC] list are determined through:

· governmental and legal requirements.
· customer and internal requirements (e.g.: DGD, MPS).
· application of FMEA process (ref. AS104); in that case only [pCC] and [pSC}
confirmed as [CC] or [SC] shall be identified and carried forward to the relevant
documents (see AS104).

5.2 The [CC]/[SC] list

The purpose of the [CC]/[SC] list is to monitor and assure that all special
characteristics are effectively managed during the product and process
development, and during ongoing production. It is a mandatory document that shall
be used for each product.

The [CC]/[SC] list shall be retained in the PLM (Product Lifecycle Management)
system.

If there are multiple manufacturing processes and/or manufacturing sites for the
same product design, the responsible plant process engineer has to discuss an
update of the [CC]/[SC]-list with the DA based on the review of the PFMEA and
Control Plan at the relevant sites.

The minimum requirements to the format of the [CC]/[SC] list are shown in Appendix
B.

More information / columns could be added as a column describing standard

measurement methods. Columns mentioning functions and requirements may be
added to ensure traceability between product function and characteristics.

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Autoliv Standard
Special Characteristics Classification – AS052

5.3 Controlling [CC]/[SC]

5.3.1 During development

All [CC/SC]s shall be verified and validated during Design Verification (DV) and / or
Product Validation (PV), before PPAP.

All special characteristics determined as [CC] and [SC].during FMEA activity (see
AS104) shall be carried forward to a drawing and/or to a specification, to a [CC]/[SC]
list, a control plan and where applicable to the Standardized Work Instruction (SWI).

In some cases, (C)DA could decide to carry forward [pCC] and [pSC] for information
to the [CC]/[SC] list, e.g.: for components that may be manufactured with a process
variant and/or a technology varying from the one usually applied. It may allow the
DA to reclassify a [pCC] and [pSC] in a [CC] and [SC].

If [CC]/[SC] is a process characteristic identified in a PFMEA, then this special

characteristic shall be carried forward to a process specification, a [CC]/[SC] list to a
Control plan and if applicable to the Standardized Work Instruction but not
mandatory to a drawing.

On some specific components and processes the measurement of a characteristic

may require a specific method to prevent variability linked to various supplier
laboratories.

This method shall be evaluated and approved by an authorized Autoliv

representative (Supplier Quality, Production Quality, Design Authority) and may be
recorded in a Measurement Agreement (ref. Measurement Agreement Sheet).

The Measurement Agreement Sheet is a supplement to the [CC]/[SC] list. It has to

be part of the PPAP and shall be stored in PLM.

The supplier shall evaluate and implement the measurement method evaluated and
approved by Autoliv and other appropriate controls on characteristics related to their
processes.

The supplier shall evaluate their processes and further identify, document and
control additional characteristics contributing.

5.3.2 During PPAP (Production Part Approval Process)

All [CC/SC]s on the drawings, control plans and other documents (i.e. maintenance
instruction, Standard Work Instructions, etc.) shall be referenced in the PPAP
documentation, and proven capable.

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Autoliv Standard
Special Characteristics Classification – AS052
This initial process capability study is to evaluate:

· conformity of characteristics to the specified requirement.

· the effect of tool / process variation on these characteristics.

If a material / material characteristic is a [CC] or [SC], then a material certificate shall

be provided.

If [CC]/[SC] is an attributive characteristic directed by the customer (Flammability,

Dynamic Tests acc. ECE R16, Airbag Inflation Tests, etc.) test methods and sample
sizes used to prove initial capability in DV and PV should be approved by DA.(Local,
Regional or depending on the scope of the project and even Global if required).

Capability studies shall be performed according to the AIAG manual Statistical

Process Control (SPC), and measurement equipment shall be proven acceptable
according to the AIAG manual Measurement Systems Analysis (MSA) /
ISO/TS 16949, latest editions.

Suppliers shall demonstrate their ability to perform capable measurement of

characteristics according to method specified by Autoliv. Evidence shall be provided
during S-APQP process.

Re-use of capability or MSA data (less than 12 months old) from existing tooling and
equipment is allowed as defined in the following flowchart (picture 5.1):

Re-use Capability
Data

Is the intention to No
use existing
Production Equipment?

Yes

Does the
Yes
new product design affect Carry-out new
any [CC] and Capability Study
[SC]?

No

Is capability/MSA Yes
data
more than 12
months old?

No

Reduce sample size, evaluate average and range,

and confirm this data fits within existing distribution.
Use existing Cpk data in PPAP documentation.

5.3.3 During serial production

All [CC]/[SC]s on the drawings and/or specifications shall be verified during serial
production.

[CC]/[SC]s verification shall be cascaded and documented to production Control

Plan and, as applicable on other documents (i.e. maintenance instruction, Standard
Work Instructions, etc.).

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Special Characteristics Classification – AS052
Frequency and sample size will be determined by the results of MSA studies,
capability studies, PFMEA and experience from similar processes.

Material and/or material characteristics designated as [CC] or [SC] shall be verified

by material certificates, which shall be available for review upon request. For non
Autoliv components, mandated by customer, PSW approval from OEM is expected,
or should be consistent with the terms of the directed source agreement. All
Materials: acc. to AS005, IMDS data to be submitted.

Changes affecting [CC] and/or [SC] verification shall be approved by DA/GDA and
others relevant functions (e.g. Production Quality, Supplier Quality).

Changes to process that could affect the [CC] or [SC] shall be approved by Industrial
/ Process Engineering.

Ongoing verification of capability of attributive characteristics (e.g. COP-testing etc.)

should be approved by DA/GDAs.

As a result of evaluation of their processes, the supplier shall identify and control
additional special characteristics, via the control plan and other applicable
documents (i.e. maintenance instruction, Standard Work Instructions, etc.).

5.4 [CC/SC]s List Document Management

5.4.1 Language and Access

All new [CC]/[SC] lists shall be written in English or in dual language (local language
and English).

Since characteristics are shared between the functions, the [CC]/[SC] list may be
accessed and managed by any member of the project cross-functional team.

5.4.2 Format for project D & PFMEA

The [CC]/[SC] list record retention shall be done in PLM which shall reflect the latest
released version and shall use the [CC]/[SC] list document type for storing the
[CC]/[SC] list.

In case local software versions of the [CC]/[SC] list are used, the standard [CC]/[SC]
list excel format (Appendix B) shall be used when shared within Autoliv. All [CC]/[SC]
lists (local software version and AS052 standard template) shall be stored in PLM.

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Autoliv Standard
Special Characteristics Classification – AS052

5.4.3 Master [CC]/[SC] list

Master [CC]/[SC] list ist may be created by Design Authority to ensure a similar
handling of [CC]/[SC] lwithin Autoliv.

If existing, the use of the Master [CC]/[SC] list as an input to the FMEA shall be
ensured.

Master [CC]/[SC] list shall:

· use a specific Master [CC]/[SC] list document type for classification and storage
in PLM.
· be stored in English as an Excel file (*.xls) fulfilling format in Appendix B.

Master [CC]/[SC] list are stored in a PLM project owned by GDA / DA. A link to this
project space can be found on the Autoliv Global Intranet /Engineering / Master
Documents inventory List

Revisions of Master [CC]/[SC] list are respectively controlled by:

· Global Development / GDA / for characteristics related to product & components.

· Process Authority for Characteristics related to process.
· Commodity Supplier Quality for Specific Master PFMEA.

5.4.4 Distribution outside Autoliv

Distribution of the complete [CC]/[SC] list data outside of the Autoliv group
(customer or supplier) is strictly prohibited but can be presented to the customer
or the supplier and an extract can be provided according to the following:

· Customer: extract of [CC]/[SC] list related to Autoliv Product and/or Autoliv

Process
· Supplier: extract of [CC]/[SC] list related to component

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Autoliv Standard
Special Characteristics Classification – AS052

6 References
AS100 Autoliv Standard Autoliv Product Development System
(APDS)
AS104 Autoliv Standard Failure Mode and Effects Analysis
AS115 Autoliv Standard Corporate Design Authority (CDA)

AIAG Automotive Industry Action Group

AIAG manual Statistical Process Control (SPC)
AIAG manual Production Part Approval Process (PPAP)
AIAG manual Measurement System Analysis
ISO/TS 16949 Quality Systems – Automotive Suppliers – Particular requirements
for the application of ISO 9001
VDA 4.3

Special Characteristics Training Module Autoliv Corporate Standards Database

Product n Process Risk Management
Training Module
Measurement Agreement sheet Autoliv Corporate Standards Database
Special Characteristics Symbols’ list Autoliv Corporate Standards Database

7 Appendices

7.1 AS052 Appendix A – [CC]/[SC] – Summary

Included in this document.

7.2 AS052 Appendix B – [CC]/[SC] - list

See latest version in the Autoliv Corporate Standards database

8 Modification Index
Version Date / Author Modification
#
1 08-Jul-1997 First version released

2 05-Jun-1998 Page 4: Indicated:

for new designs:
the symbols

and

15-Feb-1999 and [ CC ] and [ SC ] for text

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Autoliv Standard
Special Characteristics Classification – AS052
as well as the symbols valid for old designs.

13-Apr-1999 Page 5: 2. Deviation approval possible (added) if Ppk

requirement is not fulfilled.

Word file (instead of Ami Pro)

14-Jan-2000 Page 2: 1.) last line - the handling of CCs and SCs
It is valid for all new designs from the date of release as
well as for all Major Changes (Engineering level change)
on existing parts. (added)
Page 3: Headline: Definition according to General Motors NAO
defined in (omitted) QS 9000
Definition CC: emissions, noise, radio frequency
interference, etc. ... (omitted)
Page 5: 4. + 5. Instead of “no” now “as necessary” for SCs
Pages: 6 / 7 / 8 / 9 / 10 (completely added)
4 30-Jun-2003 Completely revised issue

4.1 14-Jan-2004 Page 9: 5.4 added

6 - References: Production Part Approval Process (PPAP)
(added)
Page 10: new Appendix A
4.2 03-Sep-2004 5.3.1 completely revised
Appendix A: More clarified
Appendix B: New section “Data” (Cpk/Ppk) added, new section
“Optional” added
4.3 22-Jun-2005 Page 6: One arrow corrected in Procedure flowchart.
Page 7: Customer requirements added to last sentence.

5.0 18-May-2010 New release: Special Characteristics determination is transferred to

F.Germain, M. FMEA versus CC/SC list previously. pCC and pSC were created in
Dahlén AS104.

5.1 2-May-2016 5.3.1 updated (Measurement Agreement Sheet)

/W. Wulfers 5.3.3 updated (Material Certificates for Non Autoliv Components)
Appendix A, 3.1 & 3.2 completely revised

Special Characteristic Symbol´s List updated:

JLR: YS, YC and (‫ )׏‬added
Daimler DZ and DS corrected
5.2 9-Jun-2016 Table 4.1 The updated table provides improved clarity on the use and
/W. Wulfers appearance of the special characteristic symbols.

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 AS052 Appendix A
[CC]/[SC] Summary

[CC] [SC]
1 When applied May affect a product safety, operator safety and/or May affect a product form, fit or function significantly (other
(see §4 for compliance with regulatory (governmental and legal) than safety and regulatory) or has other valid reasons for
definition of requirements. control and documentation.
[CC] & [SC].
2 Is a deviation Yes, temporarily (see PPAP manual) Yes, temporarily (see PPAP manual)
approval
possible from
the
characteristic
specified on
the drawing?
3 Evidence for
new design
and new tool
(drawing
release after
30.06.2003)
3.1 Evidence for Initial capability Ppk > 2.0 Initial capability Ppk > 1.67
PPAP approval OR OR
ANY or ALL OF ANY or ALL OF
other methods more appropriate for certain processes or other methods more appropriate for certain processes or
products may be used with prior approval from the products may be used with prior approval from the
responsible Design Authority: responsible Design Authority:
• Poka-Yoke • Poka-Yoke

• 100% detection of defects • 100% detection of defects

• Certification in case of Homologation, DOT approval, • Certification in case of Homologation, DOT approval, CE
CE approval, Flammability acc. FMVSS 302, Material approval, Flammability acc. FMVSS 302, Material Certificate,
Certificate, VDA 4.3 or other customer special VDA 4.3 or other customer special characteristic certification
characteristic certification requirements etc. requirements etc.

Reduced capability level shall be defined for specific Reduced capability level shall be defined for specific cases
cases by responsible Design Authority based on overall by responsible Design Authority based on overall safety
safety margin analysis. The respective capability level margin analysis. The respective capability level has to be
has to be documented on the Drawing. documented on the Drawing.
3.2 Evidence in Continuous capability Cpk > 1.67 for a stable process, if Continuous capability Cpk > 1.33 for a stable process, if
running verified by: verified by:
production • SPC (Statistical Process Control) • SPC (Statistical Process Control)
OR OR
ANY or ALL OF ANY or ALL OF
other methods more appropriate for certain processes or other methods more appropriate for certain processes or
products may be used with prior approval from an products may be used with prior approval from an
responsible Design Authority: responsible Design Authority:
• Poka-Yoke • Poka-Yoke

• 100% detection of defects • 100% detection of defects

• Certification in case of Homologation, DOT approval, • Certification in case of Homologation, DOT approval, CE
CE approval, Flammability acc. FMVSS 302, Material approval, Flammability acc. FMVSS 302, Material Certificate,
Certificate, VDA 4.3 or other customer special VDA 4.3 or other customer special characteristic certification
characteristic certification requirements etc. requirements etc.

Reduced capability level shall be defined for specific cases Reduced capability level shall be defined for specific cases
by responsible Design Authority based on overall safety by responsible Design Authority based on overall safety
margin analysis. The respective capability level has to be margin analysis. The respective capability level has to be
documented on the Drawing. documented on the Drawing.
4 Evidence for
existing design
from before
2003-06-30,
or existing tool

Continues on the next page

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 AS052 Appendix A
[CC]/[SC] Summary
Cont.
4.1 Evidence for Initial capability Ppk > 1.67 Initial capability Ppk > 1.67
PPAP approval OR OR
ANY or ALL OF ANY or ALL OF
other methods more appropriate for certain processes or other methods more appropriate for certain processes or
products may be used with prior approval from the products may be used with prior approval from the responsible
responsible Design Authority: Design Authority:
• Poka-Yoke • Poka-Yoke

• 100% detection of defects • 100% detection of defects

• Certification in case of Homologation, DOT approval, • Certification in case of Homologation, DOT approval, CE
CE approval, Flammability acc. FMVSS 302, Material approval, Flammability acc. FMVSS 302, Material Certificate,
Certificate, VDA 4.3 or other customer special VDA 4.3 or other customer special characteristic certification
characteristic certification requirements etc. requirements etc.

Reduced capability level shall be defined for specific Reduced capability level shall be defined for specific cases by
cases by responsible Design Authority based on overall responsible Design Authority based on overall safety margin
safety margin analysis. The respective capability level analysis. The respective capability level has to be
has to be documented on the Drawing. documented on the Drawing.
4.2 Evidence in Continuous capability Cpk > 1.33 for a stable process, if Continuous capability Cpk > 1.33 for a stable process, if
running verified by: verified by:
production • SPC (Statistical Process Control) • SPC (Statistical Process Control)
OR OR
ANY or ALL OF ANY or ALL OF
other methods more appropriate for certain processes or other methods more appropriate for certain processes or
products may be used with prior approval from an products may be used with prior approval from an responsible
responsible Design Authority: Design Authority:
• Poka-Yoke • Poka-Yoke

• 100% detection of defects • 100% detection of defects

• Certification in case of Homologation, DOT approval, • Certification in case of Homologation, DOT approval, CE
CE approval, Flammability acc. FMVSS 302, Material approval, Flammability acc. FMVSS 302, Material Certificate,
Certificate, VDA 4.3 or other customer special VDA 4.3 or other customer special characteristic certification
characteristic certification requirements etc. requirements etc.

Reduced capability level shall be defined for specific Reduced capability level shall be defined for specific cases by
cases by responsible Design Authority based on overall responsible Design Authority based on overall safety margin
safety margin analysis. The respective capability level analysis. The respective capability level has to be
has to be documented on the Drawing. documented on the Drawing..

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