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1、I Verband derV|AutomobilindustrieQuality Management in the Automotive IndustryPart 2 Technical cleanliness in assemblyEnvironment,Logistics,Personnel and Assembly Equipment1st edition 2010Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:32Nur zur internen Verwendung fur ZF
2、 Friedrichshafen AG bestimmt.Technical cleanliness in assemblyEnvironment,Logistics,Personnel and Assembly Equipment1st edition 2010English edition,April 2011Verband der Automobilindustrie e.V.(VDA)Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:32Nur zur internen Verwend
3、ung fur ZF Friedrichshafen AG bestimmt.ISSN 0943-9412Print 2010/10English edtion,print 2011/04Copyright 2010 byVerband der Automobilindustrie e.V.(VDA)Qualitats Management Center(QMC)10117 Berlin,Behrenstr.35Overall production:Henrich Druck+Medien GmbH60528 Frankfurt am Main,Schwanheimer StraBe 110P
4、rinted on chlorine-free bleached paperDokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:32Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.Non-binding VDA Standard recommendationThe Association of the German Automotive Industry(VDA)recommends its members to ap
5、ply the following standard for the implementation and maintenance of q uality management systems.Exclusion of LiabilityVDA volumes are recommendations available for general use.Anyone applying them is responsible for ensuring that they are used correctly in each case.This VDA volume takes into accou
6、nt state of the art technology,current at the time of issue.Implementation of VDA recommendations relieves no one of responsibility for their own actions.In this respect everyone acts at their own risk.The VDA and those involved in VDA recommendations shall bear no liability.If during the use of VDA
7、 recommendations,errors or the possibility of misinterpretation are found,it is req uested that these be notified to the VDA immediately so that any possible faults can be corrected.Referenced standardsThe q uotations from standards identified with their DIN number and issue date are reproduced with
8、 the permission of the DIN Deutsches Institut fur Normung e.V.The version with the latest issue date,available from the publishers Beuth Verlag GmbH,10772 Berlin,is definitive for the use of the standard.CopyrightThis publication including all its parts is protected by copyright.Any use outside the
9、strict limits of copyright law,is not permissible without the consent of VDA-QMC and is liable to prosecution.This applies in particular to copying,translation,microfilming and the storing or processing in electronic systems.TranslationsThis publication will also be issued in other languages.The cur
10、rent status must be req uested from VDA-QMC.Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:323Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:324Nur zur internen Verwendung fur ZF
11、Friedrichshafen AG bestimmt.Foreword-Using the guidelineAs clients of the Fraunhofer IPA,members of the MontSa industrial alliance are given the jointly written version of a work paper concerned with cleanliness in assembly in the form of a consolidated final report.The final report forms the basis
12、of a guideline which is planned to be released by the VDA Quality Management Center(VDA-QMC)as VDA Volume 19.2 with the title Technical cleanliness in assembly-Environment,Logistics,Personnel and Assembly eq uipment.The right to publish the guideline has been transferred to the VDA-QMC by mutual con
13、sent of the cooperation partners.No rights exist to claim commission from revenues obtained by the VDA-QMC from distribution of the guideline.The final report of the MontSa industrial alliance is the property of the participating companies and may be consulted by the companies to clarify internal q
14、ueries.It is forbidden to publish the final report for commercial purposes.Copying,reproduction or sale of the final report-including extracts thereof-by companies other than those participating in the industrial alliance shall not be permitted.Our thanks go to the following companies,in particular
15、to the employees involved,for their participation in the preparation of this document:Arnold UmformtechnikForchtenbergBMW GroupMunichContinental Chassis&SafetyFrankfurtContinental automotiveRegensburgContitechKarbenDaimler AG(PKW)StuttgartDaimler AG(NKW)WorthEaton Fluid PowerBaden BadenETO MAGNETIC
16、GmbHStockachEJOT GmbH&Co.KG.Bad BerleburgFTE automotive GmbHEbernGetrag Getriebe und ZahnradfabrikNeuensteinGlaser GmbHHorbDokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:325Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.Hydac Filtertechnik GmbHSulzbach/Sa
17、arJ.Eberspacher GmbH&Co.KGEsslingenINA Schaeffler oHGHerzogenaurachKnorr-Bremse AGAldersbachMahle Filtersysteme GmbHStuttgartMann und HummelLudwigsburgMAN NutzfahrzeugeNurnbergMaurer Magnetic AGGruningen(CH)Pall GmbHDreieichRobert Bosch GmbHSchwieberdingenTRW Lucas Automotive GmbHKoblenzWitzenmann G
18、mbHPforzheimVolkswagen AGWolfsburgVOSS Automotive GmbHWipperfurthZF Friedrichshafen AGFriedrichshafenThanks are also due to all who have provided suggestions for improvement as well as those organizations represented in the editorial circle.Stuttgart/Berlin,September 2010FraunhoferVERBAND DER AUTOMO
19、BILINDUSTRIE E.V.(VDA)Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:326Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.Index of Contents PageA SCOPE OF APPLICATION AN VALIDITY 111 Background 112 Scope of application 142.1 Particles 142.2 Application and i
20、mplementation 153 Exclusions 15B DESIGNING A CLEAN ASSEMBLY FACILITY 171 Introduction 172 Fundamentals 172.1 Particle generation and mechanisms of transport 172.2 Grouping particle sources 192.3 Basic principles for controlling and minimizing damagingparticles 213 Design 233.1 Concept 233.2 Applicat
21、ion 273.3 Implementation 29A.B Annex 31A.B.1 Planning a clean assembly facility 31A.B.2 Process chain analysis 32C ENVIRONMENT 331 Introduction 332 Fundamentals 343 Design 343.1 Measures an recommendations-constructional 353.1.1 Classification of clean areas 353.1.2 Selecting the cleanliness grade(C
22、G)373.1.3 Localized clean areas 423.1.4 Layout 443.1.5 Materials and surfaces 443.1.6 Floors,ceilings and walls 453.1.7 Doors,gates,locks,entrances,windows 483.1.8 Pathways and storage areas 483.1.9 Supply technology/installations 483.1.10 Environmental atmosphere 493.2 Measures and recommendations-
23、operative 503.2.1 Accompanying/supplementary measures 503.2.2 Maintaining cleanliness 513.2.3 Staff 524 Measuring environmental influences 52Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:32 Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.A.C Annex 53A.C.1
24、 Explanations of aireborne particles 53D LOGISTICS 551 Introduction 552 Fundamentals 562.1 Packaging 562.2 Logistics processes 583 Design 593.1 Constructionel measures 593.1.1 Packaging 593.2 Operative measures 703.2.1 Cleaning procedures for packaging 703.2.2 Inspection of packaging means 713.2.3 R
25、esponsibilities-packaging specifications 723.2.4 Transport and lock concepts 723.2.5 Storage 773.2.6 Unpacking and commissioning 78A.D Annex 79A.D.1 Small load carriers-SLCs 80A.D.2 Plastic bag 81E PERSONNEL 821 Introduction 822 Fundamentals 843 Qualification and clothing 863.1 Measures and recommen
26、dations-conceptual 863.1.1 Training with focus on assembly cleanliness 863.1.2 Clothing 883.1.3 General rules 903.1.4 Logistics 943.1.5 Keeping work areas clean 973.2 Accompanying measures and considerations 983.2.1 Mixed tasks 993.2.2 Displacement through contact 1003.2.3 The worker as an activates
27、 and remover of particles 1013.2.4 Examples of typical contamination risks 102F ASSEMBLY EQUIPMENT 1031 Introduction 1032 Fundamentals 1043 Design 1063.1 Measures and recommendations-constructional 1063.1.1 Fundamental design principles 106 Dokument wurde bereitgestellt vom VDA-QMC Internetportal am
28、 25.05.2011 um 08:32Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.3.1.2Materials and surfaces1073.1.3Basic design1073.1.3.1Housing1093.1.3.2Manual Workstations1113.1.4Operating utilities1133.1.4.1Operating media and media supply technology1133.1.4.2Auxiliary materials1143.1.4.3Test
29、fluids and functional liq uids1163.1.4.4Transport systems,handling systems,feeding andsingularization1163.1.4.5Workpiece carriers and workpiece receivers1183.1.4.6Tools and grippers1183.1.5Assembly processes1203.1.6Assembly-integrated cleaning1223.1.6.1Area of application1233.1.6.2Characterizing sel
30、ected cleaning procedures1253.2Measures and recommendations-operative1363.2.1Accompanying/supplementary measures3.2.2Start up1373.2.3Operation1393.2.4Care(cleanliness maintenance)1393.2.5Maintenance/repair1393.2.6Installation/(re)fitting1403.2.7Process approval/clearance for operation1413.2.8Downtim
31、es1413.2.9Putting into storage1413.2.10Rework142A.F.Annex142A.F.1Comparison of alternative methods for cleaning con rodsA.F.2Magnetism as a disturbance variable143GDETERMINATION OF CLEANLINESS IMPACTS1441Introduction1452Environmental and air cleanliness1462.1Test techniq ues1462.2Procedure1492.3Docu
32、mentation150Surface cleanliness1523.1Test techniq ue1533.2Procedure1563.3Documentation156Cleanliness of liquids1564.1Test set-up1564.2Procedure157Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:32Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.5Cleanliness
33、of assembly processes1585.1Test techniq ues1585.2Procedure1595.3Documentation160A.GAnnex161A.G.1Procedure for particle trap tests161A.G.2Visualizing sedimentation counts(lllig values)165HTERMS AND ABBREVIATIONS1661Terms and definitions1662Abbreviations and symbols1713References172IANALYSIS OF POTENT
34、IALS1731Contents1732Aim1733Procedure1744Question List174JPLANNING EXAMPLE1821Overview1822Introduction1832.1System components1832.2Construction of the system1832.3Design and organization of a cleanliness zone184Assembly environment1853.1Selecting the right cleanliness grade1853.2Design and organizati
35、on of a cleanliness zone186Logistics concept1864.1Outer packaging and lock systems1864.2Inner packaging of delivered parts1885Staff1885.1Clothing1885.2Qualification1896Assembly processes1896.1Designing assembly processes1896.2In-line cleaning1917Operating utilities1917.1Assembly station1917.2Feeding
36、 techniq ue/singularization1938Determining and assessing cleanliness influences1948.1Environment1948.2Assembly station195Dokument wurde bereitgestellt vomVDA-QMC Internetportal am 25.05.2011 um 08:3210Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.A:SCOPE OF APPLICATION AN VALIDITYA.
37、1 BackgroundThe guideline is intended as an aid for planners and q uality management staff involved in the planning of new processes and seq uences or the optimization of existing ones in assembly areas and their environments where cleanliness is a critical factor.In many fluid circuits found in aut
38、omobiles(e.g.fuel systems,brake circuits,lubricating and hydraulics systems,cooling and air-conditioning systems,air intakes or exhaust systems and further treatment)as well as in mechanical and electronic units,contamination through particles may cause functional impairments.In such cases,the separ
39、ate system components are generally cleaned after manufacture and the level of cleanliness needed for them to function is specified and tested(VDA 19 Inspection of technical cleanliness-particulate contamination on functionally-relevant automotive parts).In subseq uent manufacturing steps,there is a
40、 danger that the initially clean components become recontaminated through transportation,storage,provision and especially assembly as a result of the generation or entry of particles.If such sensitive system components cannot be cleaned after assembly,there is a risk that particulate contamination w
41、ill remain in the end-product and impair its function and that the cleanliness specification of initially-clean separate parts cannot be upheld.Fig.A.1:Contamination of components and aggregates/assemblies duringmanufacturing processes.Focus of the guideline in the field of assembly.Dokument wurde b
42、ereitgestellt vom.VDA-QMC Internetportal am 25.05.2011 um 08:32Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.The aim of the guideline is to prevent the generation of critical particulate contamination at sensitive sites,to remove unavoidable particles and to protect components and a
43、ssembled systems against the entry of particles from the surroundings.As not every particle source in a considered environment is automatically critical to the function of a completed product,the guideline also aims to name the relevant sources.This is req uired in order to take the correct technica
44、l and cost-effective measures and to avoid unnecessary costs having no appreciable benefit for the end-product.As well as aiming to fulfill the technical aims,the guideline also serves to standardize procedures for planning and optimizing cleanliness-sensitive assembly areas.Req uirements for the me
45、asures to succeed and thus the starting point of the guideline are:-A cleanliness specification for components and aggregates,i.e.finding out which particles may be critical to functions.-Single parts or aggregates which fulfill the cleanliness specification(e.g.after final cleaning in mechanical pr
46、oduction).Fq uirement Cleanliness specification Technically clean single componentsMontSa Guideline；Aim Clean assembly Technically clean-；end-productsFig.A.2:Req uirements and aims of the guideline for cleanliness inassembly.Current state of knowledge and technologyIn many industries where cleanline
47、ss is crucial to product q uality,standards,guideline or norms for cleanliness-suitable manufacturing have been established,e.g.in the semiconductor and pharmaceutics industries or in medical technology.In the field of technical cleanliness,i.e.the avoidance of functionally critical particles in the
48、 automotive and supplier industry,up till this year standards for testing the technical cleanliness of components have existed but no guidelines regarding their manufacture or subseq uent processing.The measures and aids req uired to ensure appropriate cleanliness levels in assembly processes and th
49、eir environment are mainly concerned with the avoidance of the particles considered to be critical.For this reason,乙 VDA-QMC Internetportal am 25.05.2011 um 08:32 Nur zur internen Verwendung fur ZF Friedrichshafen AG bestimmt.measures used for this purpose in other industries cannot generally be app
50、lied in the automotive and supplier industry or only be implemented after careful testing.Also,the adoption of solutions from other industries and/or applying them to solve other problems is often associated with extensive costs and may not improve technical cleanliness levels.For example,many measu