执行欧盟ELV法规零部件合规流程.doc

上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co.执行欧盟ELV法规零部件合规流程编号： WD-7.3-TCBO-002版本：1.00 1、目的本文目的在于定义执行欧盟ELV 法规零部件合规流程。所有执行欧盟ELV 法规零部件必须符合2000/53/EC 报废汽车指令。本文旨在指导用户达成ELV 合规。其他与ELV相关的指令如REACH1907/2006/EC和RRR2005/64/EC应予以作为参考。2、适用范围本文的范围将包含SMC各功能块职责、零部件合规流程、部件检测、IMDS 递交和进行PPAP要求等。3、定义以下缩写将在本文中使用到IMDS 国际材料数据系统MDS 材料数据表单ELV 报废汽车DRE 设计发布工程师SQE 供应商质量工程师PPAP 产品零件认可程序SOR 需求综述RRR 可再回收利用率GADSL 全球汽车申报物质清单DQS 数据质量标准EU 欧盟EDX 能量分散X 射线仪ICP 电感耦合等离子体质谱仪4、责任本流程将涉及以下功能块。材料工程 材料工程师产品工程 设计发布工程师采购部 采购员质保部 供应商质量工程师编号： WD-7.3-TCBO-002版本：1.00第 1 页 共 10 页工程支持部 法规工程师 系统维护工程师试验认证部 认证工程师 试验工程师编制日期: 2009.4.20审核日期: 2009.4.27批准日期：2009.4.28生效日期：编制: 何玉松审核: 羊军批准: 张觉慧200 DRE负责所发SOR中包含ELV指令相关信息，协同采购部门告知供应商ELV指令的需求，按项目进度要求供应商提交MDS表单并审核批准，确保零部件材料以及材料标识合规，并将可疑零部件反馈给试验工程师进行抽查检测。4.2 采购部负责要求供应商签署ELV合规承诺书并履行ELV合规义务，协同产品工程师告知供应商ELV指令需求，推动ELV相关工作的开展。4.3 材料工程师负责对DRE的MDS表单审核工作提供技术支持，计算和平衡整车有害物质总量和RRR结果，并根据数据报告与DRE共同确定整改零件及方案。4.4 SQE负责审核PPAP中包含已被DRE批准的供应商零部件MDS表单，且零部件材料标识符合SMTC-90007要求；并负责进行SOP生产零部件ELV合规抽查，确保SOP生产件与ESO工程样件一致性。4.5试验工程师负责根据本文定义的测试标准值（表1）对DRE确定的可疑ESO零部件进行抽查检测，并反馈测试结果给DRE。对不符合零部件必须要求供应商进行整改；认证工程师负责整理ELV合规文件以进行车辆型式认证。4.6法规工程师负责跟踪欧盟ELV相关法规动态，进行供应商ELV合规承诺书确认和归档；系统支持工程师负责ELV相关系统的建立和维护，按需求提供系统操作培训。5、规定5.1 DRE在设计过程中应参考SMTC 90010标准，并在制定执行欧盟ELV法规零部件SOR中，包含以下ELV有关的声明： 所有部件必须满足2000/53/EC指令的最新版本，包括修订本中要求； 所有部件必须满足SMTC-90007最新版本中有关材料识别和汽车塑料和橡胶件标识的要求； 所有部件必须满足SMTC-90008最新版本中有关汽车零部件和材料中禁/限用危险物质的要求； 所有执行欧盟ELV法规的部件必须通过IMDS系统递交MDS表单，且必须在不迟于SOP前6个月完成递交或根据SMC要求进行递交； 所有部件必须满足GADSL（全球汽车申报物质清单）的要求，具体GADSL可在获取。5.2 根据2009年1月7日最新颁布的欧盟2009/01/EC指令，SAIC Motor必须与供应商进行ELV合规约定，由采购部要求供应商签署ELV合规承诺书。供应商必须意识到其在ELV合规工作中应尽的义务和涉及不合规零部件所必须承担的责任。5.3 DRE/材料工程师根据SMTC DQS（V1.0）（附录2）和IMDS准则开展SMC员工MDS报告审核培训。针对SMC员工的培训文件由材料工程师/系统维护工程师制定并下发，针对供应商的MDS报告递交培训及培训文件下发则由SQE负责。5.4 DRE根据项目进度要求各自零部件供应商进行MDS表单递交。此要求应包括以下内容： SMTC IMDS SMTC DQS（V1.0） MDS表单递交时间进度5.5 零部件审核流程5.5.1 DRE根据SMTC DQS（V1.0）对供应商提交的MDS表单进行审核批准。5.5.2 试验工程师采用快筛设备EDX对DRE确定的可疑ESO零部件件进行抽查检测，测试标准参见表1。5.5.3 SQE采用快筛设备EDX或通过具备ISO/IEC 17025-2005资质的第三方实验室对SOP生产零部件进行抽查检测，确保SOP生产件与ESO工程样件一致性。测试标准参见表1。表1 EDX快筛设备测试标准通过（）不通过（）不确定Pb,*Cr,Hg700ppm1300ppm700-1300ppmBr300ppm500ppm300-500ppmCd70ppm130ppm70-130ppm注释：1、通过=零件合规，不再需要进一步确认是否合规；2、不通过=零部件不合规，直接要求供应商整改，零部件不准予出口至欧盟；3、不确定=考虑到可能出现的检测错误，需采用ICP进一步检测是否合规；4、采用EDX分析，6价铬，PBB，PBDE只能检测出元素级别。例如，EDX不能区别Cr3和Cr6，只能检测出总铬量。EDX不能确认PBB/PBDE，只能确定总溴量。因此，均需设定更低级别的ppm值。5.6 只有供应商的零部件的MDS表单被DRE审核批准后，DRE才能对零部件进行ESO认可。5.7 只有供应商零部件的MDS表单被DRE审核批准后，供应商才允许进行PPAP。SMC PPAP文件中必须包含此要求，没有批准的IMDS表单的零部件不能予以批准生产。6、存档文件 无7、评审与更改上海汽车ELV小组将根据本流程的适用性和有效性等情况，每年做出修订。8 、分发本流程分发第4节定义的所有SMC相关部门及分支机构。9、附件附件1 SMC ELV 零件审核流程附件2 SMTC IMDS DQS（数据质量标准）（V1.00）10、其他适用材料SMTC 90007 汽车塑料件、橡胶件和热塑性弹性体件的材料标识与标记SMTC 90008 汽车零件和材料中禁用限用危险物质SMTC 90010 汽车零部件回收利用设计指南11、文件修订记录版本换版/修订记录编制/修订人修订日期1.00新编制何玉松Wormald.Jason20090420附录1 SMC ELV 零件审核流程责任部门工作流程输出内容DRE(所有)采购部/供应商供应商DRE供应商DRE/TVSQEDRESQE递交MDS表单定点供应商开发零件/签署合规承诺书编制或修改技术文件，零件增加ELV要求SOR发布/更新 审核MDS表单PPAP审核 零件试制 信息输出ESO 审核供应商/材料更改SOPELV生产一致性检测EWO更改图纸SOR承诺书 材料数据附录2 SMTC IMDS DQS（数据质量标准）（V1.00）1. 零件结构完整，层次正确，零件号和零件名正确。零件名称应和图纸相符或相近。备注：1）只需递交一级零件，每一个一级零件一张表单。2）车身漆，密封胶，密封条等未知使用重量的材料或零件按照半成部件递交。3）零件状态为最终产品状态，不得出现样件状态。参考文件： IMDS 准则 0012. 申报零件称重重量和材料重量，零件的重量公差要求参考下表。3. 正确申报材料类型和重量，符合的标准等，部分材料需要申报材料供应商及牌号，是否标识。 符合以下条件的材料, 需申报材料供应商及牌号：塑料：100 克橡胶和弹性体：200 克金属材料：均需要申报符合以下条件的材料，需进行标识：塑料：100 克橡胶和弹性体：200 克/举例如下： 4. 申报所有的材料与物质信息，并符合GADSL 对禁用和限用物质的要求，符合SMTC 90008 ANNXE 赦免范围的材料,在Application 中选择相应的赦免项。参考文件：举例如下：5. 典型材料中物质的含量申报方法参考IMDS准则 003-021。参考文件：这些文件涉及了各种复杂或特殊零件的申报方法，如金属镀层，紧固件，润滑油，密封材料，汽车灯等。6. 使用通配符申报保留物质（最大值不得超过材料重量的10%），必须说明保留部分满足GADSL 的要求。当使用通配符如“misc, not to declare”或“confidential substance”等申报保密物质时，必须申明材料满足GADSL 的要求。在材料等级的Remark 框中可以填写以下申明：“此材料的配方符合GADSL 对禁用和限用物质含量的要求”。我们比较推荐将声明写在这个位置。二级供应商向一级供应商递交材料信息，也只有将申明写在此栏中OEM 才可看到。也可将其他OEM 的标准写在申明中，但GADSL 必须提及。7. 完整申报供应商及接受方信息，供应商信息包括公司名称，DUNS 代码，联系人姓名及电话，电子邮箱。接受方信息包括零件名，零件号，图纸号，供应商代码等。供应商代码要求和DUNS 代码一致，正确的格式为XX-XXX-XXXX。举例：供应商及联系人信息见下表接受方信息见下表：8. IMDS 表单被拒绝再次提交时，应在原来的版本基础上更改，采用新的版本号进行重新提交。同一零件号的IMDS 表单IMDS 代码应保持一致。9. 供应商根据零部件所供应部门将IMDS表单发送至对应组织单元（SMC 各组织单元标识符见下表），并及时通知负责DRE进行IMDS表单审核与批准。SMC 各组织单元IMDS 标识符部门名称IMDS组织单元标识符车身部87142底盘部87143电子电器部87144内外饰部87145发动机部87146动力总成集成部87147变速箱部8714810. SMC 将根据后续实际使用情况对SMTC IMDS DQS（V1.0）进行修订。编号：WD-7.3-TCBO-002版本：1.00第 10 页 共 10页Compliance process for EU parts, and implementation of EU ELV regulationsNo.: WD-7.3-TCBO-002Version: 1.001 PurposeThe purpose of this document is to define an ELV compliance process for components, and implementation of EU ELV regulation. All components implementing EU ELV regulation must be compliant with directive 2000/53/EC End of Life Vehicles. The document intends to guide users through the process of ELV compliance. Other relevant Directives linked to ELV include REACH 1907/2006/EC and RRR 2005/64/EC that should be used for reference.2 ScopeThe scope of work will cover the responsibilities of SMC department, parts compliance procedure, components testing, IMDS submission and PPAP requirements etc.3 Definitions：The following abbreviations will be used within this documentIMDS International materials data system MDS Materials data sheet ELV End of life Vehicle DRE Design release engineerSQE Supplier quality engineerPPAP Production part approval processSOR Statement of requirement RRR Reusability, Recyclability, RecoverabilityGADSL Global Automotive Declarable Substance ListDQS Data quality standardEU European Union EDX Energy dispersive X-ray ICP Inductively Coupled Plasma-Mass Spectrometry 4 Responsibilities：The following areas will be involved within this process.Materials engineering Materials engineer Product engineering Design release engineerPurchasing Buyer QA Supplier quality engineerES Regulation engineer System maintenance engineer TV Validation engineer Test engineer Compiled date:2009/4/20Compiled by: He yusong Wormald.JasonAudited date:2009/4/27Audited by: Yang JunApproved date:2009/4/28Approved by: Zhang JuehuiImplemented Date:Document No.: WD-7.3-TCBO-002Version: 1.00Page 1of 10 Pages4.1Product Engineering will be responsible for developing SOR with information regarding ELV, inform suppliers jointly with Purchasing of the requirements of the ELV directive. Requesting MDS reports from supplier and giving final approval according to the project schedule, ensuring parts/materials and materials marking are compliant. Identify suspected non-compliance part to test engineer for spot-testing.4.2 Purchasing will be responsible for informing suppliers of their obligations of ELV compliance and sign off an “obligation agreement letter”. Purchasing will also inform suppliers jointly with Product engineering of the requirements of the ELV directive, and promote the relevant ELV work of the given supplier.4.3The materials engineer shall be responsible for supporting DRE for MDS reports approval, calculating and balancing hazardous substances weight and RRR rates for total vehicle, Confirming affected parts lists and developing plans for parts compliance with DRE according to the data reports. 4.4SQE will be responsible for checking MDS reports which should be approved by DRE and included within PPAP submissions and insuring material marking is complied with SMTC 90007. Also, responsible for the spot-testing of the production components to insure materials in compliance with ESO approval parts4.5 Test engineering will be responsible for testing of ESO components which identified by DRE according to the standard shown within this document (see table 1). Tests results will be provided to DRE. In case of non-compliant parts, it must be modified by the supplier; Validation engineer will be responsible for completeness of ELV documentation for type approval.4.6Regulation engineer will be responsible for tracking the latest status of EU ELV relative regulation, confirming and archiving ELV compliance “obligation agreement letter” ; System support engineer will be responsible for the establishing and maintenance of the ELV IT system, and providing system operation training when need.5 Operation procedure5.1DRE should reference the SMTC90010 document during the components development stage. If the part is implemented by the EU ELV regulation, SOR of the related components should include the following statements with regard to ELV: All components must meet the requirements of 2000/53/EC in its latest format including all amendments. All components must meet the requirements of SMTC90007 in its latest revision with regard to Material identification and marking of automotive plastic and rubber parts. All components must meet the requirements of SMTC90008in its latest revision with regard to Automotive Prohibited/Restricted Hazardous Substances for Parts and Materials. MDS reports via IMDS are required for all components implementing the EU ELV regulation. Reports must be submitted no later than six months prior to SOP or in accordance with requests from SMC. All components must comply with the requirements contained in the Global Automotive Declarable Substances List (GADSL) available at .5.2Under the latest EU legislation, 2009/01/EC - issued January 7th 2009, SAIC Motor is required to have an “obligation agreement letter” with suppliers in regard to ELV regulations. Suppliers must be made aware of their obligations and the penalties and liabilities involved with none compliance. This shall be a purchasing responsibility.5.3DRE/Materials engineer shall be responsible for training SMC employees on MDS report approval according to SMTC DQS (V1.0) （Annex 2） and IMDS guidelines. Internal literature for SMC employees shall be distributed by materials engineering/system maintenance engineer. External literature for supplier shall be distributed via SQE, and SQE shall be responsible for supplier training.5.4DRE should demand MDS reports submissions from supplier according to the project schedule. The “demand” shall include the following: SMTC IMDS DQS (V1.0). Schedule MDS submissions are required.5.5Parts approval procedure5.5.1 DRE shall check and give approval to MDS reports from suppliers, according to SMTC IMDS DQS (V1.0)5.5.2 Test engineer shall be responsible for performing testing of ESO parts which are identified by DRE via EDX equipment (detail testing standard refer to table 1).5.5.3 SQE shall be responsible for spot-testing of the production components via EDX equipment or the third laboratory which passed ISO/IEC 17025-2005, insuring materials are in compliance with the ESO approval parts. Detail testing standard refers to table 1. Table1 - Testing standard value of EDX equipmentPASS()FAIL（）In-conclusivePb,*Cr,Hg700ppm1300ppm700-1300ppmBr300ppm500ppm300-500ppmCd70ppm130ppm70-130ppmNotes：1. PASS = part is compliant, no further testing required part is deemed compliant；2. FAIL = Part is not compliant, requesting supplier modify directly. Parts are not suitable for supply into EU；3. In-conclusive= Due to possible test error more conclusive testing required via ICP； 4. During EDX analysis, hexavalent chromium, PBB (polybrominated biphenyls) and PBDE (polybrominated diphenyl ether) are detected as elemental only. I.e. EDX wont differentiate Cr3 from Cr6 only the total chrome content. EDX cannot identify PBB / PBDE levels only the bromine (Br) as an element therefore there is a need for much lower PPM levels. 5.6 Only the part has IMDS approval by DRE the parts shall be permitted to ESO.5.7 Only the part has IMDS approval by DRE the supplier shall be permitted to submit PPAP. SMC PPAP documentations must have a requirement for MDS reports to be included. Components without approved MDS reports shall not be given approval for production. 6 Archive 7 Review and ChangeThis document shall be revised annually for continuing suitability, adequacy, and effectiveness by ELV team of SAIC Motor.8 DistributionThis document should be distributed to all SMC departments defined in section 4.9 AppendixAnnex 1 SMC ELV parts approval procedureAnnex 2 SMTC IMDS DQS（V1.0）10 Related DocumentsSMTC 90007 Material identification and marking of automotive plastic, rubber and thermoplastic elastomer partsSMTC 90008 Automotive Prohibited/Restricted Hazardous Substances for Parts and MaterialsSMTC 90010 Vehicle Components Recycling/Recovery Design Guideline9 Revision RecordVersionChanges MadeOwnerRevision Date1.0Compiled NewlyHe yusongWormald.Jason20090420 Annex 1 SMC ELV parts approval procedureresponsible deptwork procedureoutput contentDRE(ALL)Purchasing Dept/SupplierSupplierDRESupplierDRE/TVSQEDRESQEDeveloping parts/Sign obligation agreement letter by selected supplierRevision or change technical paper, add ELV requirementsMDS report ApprovalSOR release/updateMDS report submit ionInformation output DV-PartsSupplier/material changeESO approvalPPAP approvalEWO changeSOPELV coherence production testdrawingSORObligation agreement letter Material dataAnnex 2 SMTC IMDS DQS（V1.00）1. Complete part information and correct tree structure, Part number, Part name. Part name should be same or similar to drawing.Note:1）Submit assembly part not sub-assembly part, one MDS per assembly part.2）Those unexpected weight of material of part such as body paint, sealer should be submitted as semi-component.3）Part status should be final status. We cant accept sampling parts.Ref file： IMDS recommendation 0012. Declare part measured weight and material weight information. Part weight tolerance should refer to weight deviation requirement, see table below.3. Correct declare material classification, weight, standard, such as SMTC, ISO, etc. some materials need declare materials supplier and code, marking or not.Need to declare supplier name and brand name if material according to standard below:Plastics：100gRubber and Elastomer: 200gMetal: AllNeed to marking if material according to standard below:Plastics：100gRubber and Elastomer: 200gFor example:4. Declare all material and substances refer to GADSL and SMTC9008 ANNXE requirement.Ref file：For example:5. Typical material substance content declared refer to IMDS recommendation 03-021.Ref file：Those files give IMDS recommendation method about complicated parts or special parts, such as metal coating, fastener, lubricant, seal strip, automotive lamp, etc.6. Declare compliance to GADSL about Misc and Jokers used in material. The maximum percentage of confidential substance should not exceed 10% mass of material.Whenever misc or confidential substances are used in a MDS, you must declare that the material in the MDS is in compliance with GADSL guidelines.At the Materials section under remarks