执行欧盟ELV法规零部件合规流程

上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 1 页 共 10 页 1 1 目的 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 2 适用范围 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 3 定义 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 4 责任 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 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 编号 WD 7 3 TCBO 002 执行欧盟执行欧盟ELVELV法规零部件合规流程法规零部件合规流程 版本 1 00 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 2009 5 7 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 2 页 共 10 页 4 1 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 5 规定 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 www gadsl org 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 3 页 共 10 页 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 1300ppm Br300ppm500ppm300 500ppm Cd70ppm130ppm70 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 6 存档文件 存档文件 无 7 7 评审与更改 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 8 分发 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 9 附件 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 1010 其他适用材料 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 4 页 共 10 页 1111 文件修订记录 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 Jason 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 5 页 共 10 页 附录附录 1 SMC ELV 零件审核流程零件审核流程 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 TV SQE DRE SQE 图纸 SOR 承诺书 材料数据 EWO 更改 SOP ELV 生产一致性检测 供应商 材料更改 ESO 审核 信息输出 零件试制 PPAP 审核 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 6 页 共 10 页 附录附录 2 SMTC IMDS DQS 数据质量标准 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 001 2 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 7 页 共 10 页 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 8 页 共 10 页 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 9 页 共 10 页 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co 编号 WD 7 3 TCBO 002版本 1 00 第 10 页 共 10 页 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87148 10 SMC 将根据后续实际使用情况对SMTC IMDS DQS V1 0 进行修订 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 1of 10 Pages 1Purpose The 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 2Scope The scope of work will cover the responsibilities of SMC department parts compliance procedure components testing IMDS submission and PPAP requirements etc 3Definitions The following abbreviations will be used within this document IMDS International materials data system MDS Materials data sheet ELV End of life Vehicle DRE Design release engineer SQE Supplier quality engineer PPAP Production part approval process SOR Statement of requirement RRR Reusability Recyclability Recoverability GADSL Global Automotive Declarable Substance List DQS Data quality standard EU European Union EDX Energy dispersive X ray ICP Inductively Coupled Plasma Mass Spectrometry 4Responsibilities The following areas will be involved within this process Materials engineering Materials engineer Product engineering Design release engineer Purchasing Buyer QA Supplier quality engineer ES Regulation engineer System maintenance engineer TV Validation engineer Test engineer Compiled date 2009 4 20 Compiled by He yusong Wormald Jason Audited date 2009 4 27 Audited by Yang Jun Approved date 2009 4 28 Approved by Zhang Juehui Implemented Date No WD 7 3 TCBO 002Compliance process for EU parts and implementation of EU ELV regulations Version 1 00 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 2 of 10Pages 4 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 3 The 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 4 SQE 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 parts 4 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 6 Regulation 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 5Operation procedure 5 1 DRE 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 www gadsl org 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 3 of 10Pages 5 2 Under 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 3 DRE 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 4 DRE 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 5 Parts approval procedure 5 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 equipment PASS FAIL In conclusive Pb Cr Hg700ppm1300ppm700 1300ppm Br300ppm500ppm300 500ppm Cd70ppm130ppm70 130ppm Notes 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 won t 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 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 4 of 10Pages 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 6Archive 7Review and Change This document shall be revised annually for continuing suitability adequacy and effectiveness by ELV team of SAIC Motor 8Distribution This document should be distributed to all SMC departments defined in section 4 9 Appendix Annex 1 SMC ELV parts approval procedure Annex 2 SMTC IMDS DQS V1 0 10 Related Documents SMTC 90007 Material identification and marking of automotive plastic rubber and thermoplastic elastomer parts SMTC 90008 Automotive Prohibited Restricted Hazardous Substances for Parts and Materials SMTC 90010 Vehicle Components Recycling Recovery Design Guideline 9Revision Record VersionChanges MadeOwnerRevision Date 1 0Compiled Newly He yusong Wormald Jason 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 5 of 10Pages Annex 1 SMC ELV parts approval procedure responsible dept work procedureoutput content DRE ALL Purchasing Dept Supplier Supplier DRE Supplier DRE TV SQE DRE SQE drawing SOR Obligation agreement letter Material data SOR release update MDS report submit ion DV Parts Supplier material change ESO approval EWO change SOP ELV coherence production test PPAP approval MDS report Approval Information output Developing parts Sign obligation agreement letter by selected supplier Revision or change technical paper add ELV requirements 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 6 of 10Pages Annex 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 can t accept sampling parts Ref file IMDS recommendation 001 2 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 100g Rubber and Elastomer 200g Metal All 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 7 of 10Pages Need to marking if material according to standard below Plastics 100g Rubber and Elastomer 200g For example 4 Declare all material and substances refer to GADSL and SMTC9008 ANNXE requirement Ref file For example 上海汽车集团有限公司乘用车分公司 SAIC MOTOR Passenger Vehicle Co Document No WD 7 3 TCBO 002Version 1 00 Page 8 of 10Pages 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