2009 Bendix Ppap Requirements Guidelines Rev 1-9-2009

Bendix Commercial Vehicle Systems LLC
Supplier Quality and Development
Bendix Production Part Approval Process

(PPAP)
2009 Bendix Requirements Guideline
REVISION HISTORY TABLE

Revision Number: Original Issue Revision # 1
Written By: Dale Stober Ed Smith
Approved By: Mike Allegrucci Mike Allegrucci
Issue Date: January 23, 2004 January 9, 2009
Approval Signature:
The 2009 Bendix Requirements Guideline for PPAPs is based Automotive

Industry Action Group (AIAG) PPAP Manual – Fourth Edition.
Recommended A.I.A.G. Reference Manuals for this Document include:
Advanced Product Quality Planning & Control Plan - APQP – Second

Edition
Potential Failure Mode and Effects Analysis – FMEA – Fourth Edition
Measurement Systems Analysis – MSA – Third Edition
Statistical Process Control – SPC – Second Edition
A.I.A.G. manuals are available through www.aiag.org

Production Part Approval Process (PPAP)
Bendix Requirements Guideline (PPAP 4th Edition)
Requirement
1. Design Records:
- For proprietary components / details
- For all other components / details
2. Authorized Engineering Change Documents
3. Customer Engineering approval
4. Design FMEA (Failure Mode and Effects Analysis)
5. Process Flow Diagram(s)
6. Process FMEA (Failure Mode and Effects Analysis)
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)
19. Supplier Change Notification and Submission Requirements for PPAP

Bendix Requirements Guideline
There are currently 19 elements that are the requirements of PPAP.

The intent of this guideline is to give clarification to the Supplier of what the
Bendix expectations are for each element requirement.
General Comments/Suggestions:
• All 19 requirements are to be addressed, regardless of level of submission.
• Page 1 of the PPAP Submission Package is recommended to be an

introductory page. It should include: Part Name; Part Number; Drawing
Number; Engineering Change Level; Engineering Change Level Date;
Supplier Name; Supplier Code; Supplier Street Address, City, State and Zip
Code; Supplier Phone Number; Supplier Fax number; Customer Name
(BCVS), and the using plant that the supplier is submitting the PPAP
package to.
• Any element requirement that is not included or does not apply is to have a
page stating such included under the appropriate tab in the PPAP submission
package.
• Note that the requirements of AIAG PPAP Fourth Edition, Appendix H, applies to
BCVS products (Truck Industry-Specific Requirements).
• The APQP Core Tools Forms diskette is available to guide the supplier through the
part approval process (contact your BCVS Supplier Quality Development
representative).
• The supplier can expect to have the submitted PSW form, once approved
by Bendix, returned to them via fax (be sure to include appropriate fax
number on introduction page).
• Production part approval records, regardless of submission level shall be

maintained for the length of time that the part is active plus one calendar
year.
• All Drawings, Specs, and other supplemental information contained herein

as examples, is strictly for reference purposes only.

1. Design Records:
Hard copies of the following items are to be submitted with the PPAP package:
• Engineering Drawings
• Process, Material and Engineering Specifications
• Design Records are required for all components and details e.g. where the part is
a machined casting, the machining supplier is responsible to produce the design
records for the casting, which includes the Supplier’s approved Part Submission
Warrants and all Design Records for all sub-supplier parts.
• Where the design record is in electronic format, the supplier shall still provide a
hard copy of those documents.
As an example, reference the Bendix prints and associated specs included in this
document (element # 9, "Dimensional Results").
Note 1: For any saleable product there will be only one design record. The
design record may reference other documents making them part of the design
record.
Note 2: A single design record can represent multiple part or assembly
configurations.
Note 3: For parts identified as “black box”, the design record specifies the
interface and performance requirements.
Note 4: For parts identified as catalog parts, the design record may consist only
of a functional specification or a reference to a recognized industry standard.
Note 5: For bulk materials, the design record may include identification of raw
materials, formulations, processing steps and parameters, and final product
specifications or acceptance criteria.
• Reporting of Part Material Composition shall be provided by the supplier when

required and this data must comply with all Bendix requirements.
• Polymeric parts must be identified with the ISO symbols such as specified in ISO
11469 (Plastics) and/or ISO 1629 (Rubber & lattices). The following weight
criteria shall determine if the marking requirement is applicable:
- Plastic parts weighing at least 110g.
- Elastomeric parts weighing at least 220g.

2. Authorized Engineering Change Documents:
• Examples include marked up drawings signed and approved by BCVS

Engineering, or MCRs where approval by BCVS Engineering has been obtained.
• PPAPs are NOT to be submitted if the design requirements have not been met.
3. Customer Engineering Approval:
• Bendix specifications may require suppliers to submit test results or samples for
evaluation by the BCVS Materials Department. Suppliers are responsible for
conforming to the requirements of BW specs either called out on BCVS
drawings, or as included as part of the Design Record prior to PPAP submission.
As an example, reference the Bendix spec, BW-128-P, section 6.0 included in

this document.
AlliedSignal AUTOMOTIVE
Truck Brake Systems
Elyria, Ohio 44036 U.S.A.
PROCESS SPECIFICATION BW-128-P
CHROMATE CHEMICAL CONVERSION FILM (ALODIZING)

FOR ALUMINUM ALLOYS
1.0 SCOPE
The purpose of this process is to produce a chemical chromate conversion film on

aluminum alloy parts to improve corrosion resistance and paint bonding
properties. This treatment shall be applied after all machining, stamping, bending
or other forming operations have been performed.
The coating will degrade at temperatures above 140° F (46°C) with subsequent
loss of corrosion resistance.
2.0 PROPERTIES
2.1 Parts treated according to this specification shall have a uniform iridescent
to brown adherent coating. A porous, powdery coating is not acceptable.
The process shall supply the corrosion resistance described under
Qualification Requirements.
3.0 PROCESS
3.1 The parts shall be placed in baskets in a manner which will minimize air
pockets and provide best drainage, when possible. Configuration of some
parts may leave an unavoidable air pocket. Certain parts alodized by outside
vendors may be rack coated in which case rack marks must be in a non-
critical location. Sealing ring grooves and seat areas are typical critical
locations.
3.2 If the conversion coating bath is heated, stirring is recommended to avoid

breakdown of chemicals in the immediate vicinity of the heating coils.
Ralph Lennerth 12/10/99 Dave Knight 12/10/99

WRITTEN DATE APPROVED DATE
REVISED SPEC. BW-128-P

DATE INIT. ECN NO. 4 SHEETS
Rev. 15: 12/10/99 RJL:dah 68216 SHEET NO. 1
PRODENGR FORM 003.DOC Mar. 29, 1994
DOCUMENTO CONTROLADO DE FORMATO ELECTRÓNICO: Antes de utilizarlo se requiere verificar el nivel de revision o la suficiencia.
CONTROLLED ELECTRONIC MEDIA DOCUMENT: Verification of revision level or adequacy is required prior to use.
Truck Brake Systems

FOR ALUMINUM ALLOYS
3.3 The first rinse following alodizing is required to remove alodize solution
and stop the action. The second rinse is a hot water rinse required to set the
alodize and produce a cure. The process is as follows:
Operation Solution Concentration Temperature Time

Clean* Alkaline, As required As required As required
Non-etching
Rinse Cold Water -- Room Variable
Alodine** Alodine 1600 (by volume) 60-130° F 1-5 Min.
0.83 oz./gal
1.5 – 2.0 pH
Rinse Cold Water -- Room Variable
Rinse Hot Water -- 180°F Max. Variable
* This cleaning step may be omitted for castings coming directly from the
Plastic Impregnation Processing Line as the castings have already been
thoroughly washed as part of that process.
** Alodine 1600 is a product of Henkle Corporation.
Alchrome #2 Alchrome #16 LX-1104/LX-1105

A. Concentration 1.5-2.0 oz/gal. 4.0 – 5.0% 1.28/0.22 oz/gal
B. pH 1.5 – 2.0 1.2 – 1.9 1.4 – 2.2
C. Temperature 70 - 100°F 80 – 100°F 85 - 110°F
D. Time 30 secs. – 3 min. 5 – 60 secs. 3 – 5 min.
A stainless steel or Koroseal lined tank is required.
3.4 Casting Impregnated per BW-108-P
If the plastic resin impregnation system is used the chromate conversion film
shall be applied after impregnation (Section 11, BW-108-P).
SPEC. BW-128-P
4 SHEETS
SHEET NO. 2
Truck Brake Systems

FOR ALUMINUM ALLOYS
3.5 Maintenance of Solutions
Individual manufacturer’s procedures shall be used to prepare and maintain

chemical content of the solutions.
4.0 QUALIFICATION REQUIREMENTS
4.1 Salt Fog Resistance
Tests shall be conducted in an approved salt fog box with 5% by weight

sodium chloride at 95°F ± 5°F per ASTM B117. Coated specimens should
be dried at room temperature for 24 hours prior to testing.
4.2 Test Option 1
Treated parts shall have a salt fog resistance at least four times that of
untreated parts.
4.3 Test Option 2
Five specimen panels of 2024-T3 aluminum 24 to 32 square inch area per

side and 0.020 minimum inches thick shall be processed along with
production parts. The panels should be subjected to the salt spray test for
168 hours with the significant surface inclined 6 degrees from vertical.
4.3.1 After completion of the test, the panels should be cleaned in warm
water up to 100°F, blown dry with unheated air and examined for the
following criteria to pass the test.
a. Up to 5 isolated spots or pits up to 0.031 inch diameter are

allowed per panel. Loss of color is permitted. Areas within 1/4
inch of an edge, identification marks and holding points during
testing are excluded.
SPEC. BW-128-P
4 SHEETS
SHEET NO. 3
Truck Brake Systems

FOR ALUMINUM ALLOYS
b. The combined surface area on the exposed surface of the five

panels shall have no more than 15 isolated spots or pits with
none larger than 0.031 inch diameter.
4.3.2 A non-etch cleaner is preferred for pre-process cleaning the 2024-T3

panels to avoid pitting and intergranular attack. If an alkaline etch is
used, an acid neutralization step should follow.
5.0 APPROVED MATERIALS AND SOURCES
Alodine 1600 Henkle Surface Technologies Madison Hts, MI

Alchrome 2 Heatbath Corp. Indian Orchard, MA
Alchrome 16 Heatbath Corp. Indian Orchard, MA
Alchrome LX 1104 (liquid) Heatbath Corp. Indian Orchard, MA
Alchrome LX 1105 (liquid) Heatbath Corp. Indian Orchard, MA
5.1 Alternate Specifications

The following specifications conform to BW-128-P
MIL – C 5541 E
DIN 50939
6.0 VENDOR TESTS AND REPORTS
6.1 Suppliers of these processes applied to Bendix products shall initially submit
the results of corrosion tests per 4.0 or submit samples of the coated
product to the Bendix Engineering Laboratory for process approval.
7.0 REJECTION
Material not conforming to the above requirements, or written modifications
thereof, shall be rejected and the vendor notified.
SPEC. BW-128-P
4 SHEETS
SHEET NO. 4
4. Design FMEA:
• If the supplier has design responsibility, the BCVS expectation is to have a

DFMEA in the AIAG compliant format submitted with the PPAP package.
• If the supplier considers their design to be of a proprietary nature, a waiver for
this requirement must be obtained from the using plant quality function prior to
PPAP submission and is to be included under this tab of the PPAP package.
• If the supplier does not have design responsibility, a page stating “Not
Applicable” is to be included under this tab of the PPAP package.
NOTE 1: A single Design FMEA may be applied to a family of similar parts.
NOTE 2: For Bulk Materials, see Appendix F. (AIAG 4 Edition)

5. Process Flow Diagrams:
• The supplier must include a process flow diagram that clearly describes the
production process steps and sequences. The process flow step numbers
should match up with the Process FMEA and Control Plan step numbers.
NOTE: Process flow diagrams for “families” of similar parts are acceptable if the
new parts have been reviewed for commonality by the organization.
6. Process FMEA:
• The supplier must include a process FMEA that is compliant to the AIAG
format.
• PFMEAs are to include ALL process steps, e.g. receiving, incoming inspection,
labeling, shipping, etc.
• All BCVS Special Characteristics must be included in the PFMEA.
• High RPN process steps should include actions to reduce them.
NOTE 1: A single Process FMEA may be applied to a process

manufacturing a family of similar parts or materials if reviewed for
commonality by the supplier.
NOTE 2: For Bulk Materials, see Appendix F. (AIAG 4th Edition)

7. Control Plan:
• Control plans for “families” of similar parts are acceptable if the new parts have been
reviewed for appropriate commonality.
• Control plan approval by BCVS prior to PPAP package submission is NOT

required.
• Regardless of the form used by the supplier, all elements of AIAG APQP
format must be addressed.
• All BCVS Special Characteristics must be included in the control plan.
Note 1: Control plans for ‘families of parts are acceptable if the new parts
have been reviewed for commonality by the organization.
Note 2: Control Plan approval may be required by Bendix.

8. Measurement System Analysis Studies:
• MSA studies are to be submitted for all gages or families of gages used to
measure the applicable product/process characteristic of the initial process
capability study.
• Where Special Characteristic requirements apply, valid MSA’s for each

specific gage used to measure the Special Characteristics must be
submitted. MSA studies for gage families are NOT acceptable.
NOTE: Gage R & R acceptability criteria are defined in the

Measurement Systems Analysis reference manual.
9. Dimensional Results:
• Dimensional results are to be included for each unique manufacturing cell or

production line and all cavities, molds, patterns, or dies.
• It is expected to have a "ballooned" drawing included with the PPAP package.
Each ballooned element of the drawing is to be numbered and correspond to the
numbering sequence on the Dimensional Results form.
As an example, reference the drawing 298725 and Dimensional Results included

in this document.
• Actual dimensional results are to be shown in the Supplier Measurement Results

column of the Dimensional Results form. Write down the actual reading (or
range) obtained (NOT "OK / Not OK").
• The OK/Not OK boxes are to be checked appropriately to indicate conformance
of the measurements obtained to the Design Record requirements.
• Drawing notes are to be included on the Dimensional Results form, along with
evaluation results.
• Dimensional results of sub-components are to be included in the PPAP
submission package (see element # 1, "Design Records of Saleable Product").
• Embedded dimensional requirements within BW specifications are to be
recorded.
As an example, reference the Bendix spec, BW-111-ES for flash, ejector pins,
surface finish, etc. requirements included in this document.
• The organization (supplier) shall identify one of the parts measured as the
“master sample”. (see section 15)
NOTE: The Dimensional Results form in Appendix C (PPAP 4th Edition) shall be
utilized for this purpose.
Production Part Approval
NOTE: TO BE USED AS AN EXAMPLE ONLY. Dimensional Test Results Page _1_of __2__
DOES NOT CONTAIN ALL INSP. ITEMS.
ORGANIZATION: SUPPLIER: Acme PART NUMBER: NUMBER: 298725
SUPPLIER / VENDOR CODE: CODE: 909152 PART NAME: NAME: Crankcase Cover
INSPECTION FACILITY Acme DESIGN RECORD CHANGE LEVEL: ECL: Rev. 7
ENGINEERING CHANGE DOCUMENTS: ECN 69978
SPECIFICATION / QTY. ORGANIZATION MEASUREMENT RESULTS NOT
ITEM DIMENSION / SPECIFICATION TEST DATE OK
LIMITS TESTED (DATA) OK
1 5.64 unspecified tolerance 5.63 - 5.65 8/12/2002 5 5.633 Unspecified tol = .010 for 2 d.p. X
per ECN. See Engineering Change
Records, section 2.0
2 Dim "F" N/A N/A N/A N/A for this part number X
3-1 Dia. .346 +/- .007 .339 - .353 8/12/2002 5 .349 - .352 X
4-1 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .035 X
See CMM Report attached
5-1 Position = .015 M, A 8/12/2002 5 True Position = .020 X
3-2 Diameter .346 +/- .007 .339 - .353 8/12/2002 5 .348 - .350 X
4-2 Position = .040 M, A, B, C, 8/12/2002 5 True Position = .026 X

6 Note 4 - .030 min depth from N/A N/A N/A Z dim for CMM probe set at 1/2 mat'l X
side opp. gasket surface thickness (.1121) from datum "A" for
(datum "A") all hole measurements.
7 .44 Radius - unspecified tol. .43 - .45 8/12/2002 5 .443 - .446 R. Unspecified tolerance = X
.010 for 2 d.p. per ECN. See Eng.
Change Records, section 2.0.
8 Dim "G" = ------- N/A N/A N/A N/A for this part number X
9 .50 Flatness Area N/A N/A N/A Dimension used for layout purposes X
only to define flatness area zone.
10 Note 1 - smooth within 32 32 - 125 8/12/2002 5 Ra 88 - 110 X
Microinch to 125 microinch as
rolled. Surface side only.
11 .009 Max flatness between .000 - .009 Max. 8/12/2002 5 Hole 1 to Hole 2 = .006 max X
adjacent holes around part. Hole 2 to Hole 3 = .008 max. X
Hole 3 to Hole 4 = .008 max. X
Hole 4 to Hole 5 = .005 Max. X
Hole 5 to Hole 6 = .007 max. X
Production Part Approval
NOTE: TO BE USED AS AN EXAMPLE ONLY. Dimensional Test Results Page _2_of __2__
DOES NOT CONTAIN ALL INSP. ITEMS.
ORGANIZATION: SUPPLIER: Acme PART NUMBER: NUMBER: 298725
SUPPLIER / VENDOR CODE: CODE: 909152 PART NAME: NAME: Crankcase Cover
INSPECTION FACILITY Acme DESIGN RECORD CHANGE LEVEL: ECL: Rev. 7
ENGINEERING CHANGE DOCUMENTS: ECN 69978
SPECIFICATION / QTY. ORGANIZATION MEASUREMENT RESULTS NOT
ITEM DIMENSION / SPECIFICATION TEST DATE OK
LIMITS TESTED (DATA) OK
18 3.44 - Unspecified Tolerance 3.43 - 3.45 8/12/2002 5 3.432 - 3.441 Unspecified tolerance = X
.010 for 2 d.p. per ECN. See Eng.
change records, Section 2.0.
22 Remove all Burrs and Sharp 0.00 Max. 8/12/2002 5 All burrs and sharp edges broken. X
Edges Allowable
25 Treatment - Rust prevent per Spec. 8/12/2002 5 Rust Ban 392 used. Material is listed X
Spec BW-104-P on Bendix BW-104-P spec.
Blanket statements of conformance are unacceptable for any test results.
March SIGNATURE TITLE DATE

2006 CFG-1003
BCVS ENGINEERING STANDARD BW-111-ES
1 of 6
NOTICE
Bendix Commercial Vehicle Systems LLC claims proprietary rights to the

information contained herein. This document is furnished in confidence with
the express understanding that neither it nor any copy thereof shall be disclosed
to others nor used for the purpose of manufacture or procurement of the article
documented herein, without written permission from Bendix.
© 2002 Bendix Commercial Vehicle Systems LLC, All Rights Reserved.
SUPERSEDES :
X
Written Date
12 70310 06-12-02 Bendix Commercial Vehicle Systems LLC

Elyria, OH 44036 JMK 06-12-02
APPROVED Date
DIE CASTING POROSITY
REV. ECN NO. DATE RJC 06-12-02
STANDARD
PRODENGR FORM 004.DOC REVISED 2000/10/17
2 of 6
1.0 SCOPE:
This Standard establishes the Bendix Commercial Vehicle Systems L.L.C. (BCVS)
acceptance limit for aluminum and zinc die castings and is a supplement to the
individual casting drawing. All requirements herein must be met, in addition to all
other requirements of the applicable drawing.
If there is a conflict between BW-111-ES and the drawing, the drawing shall prevail.
2.0 PURPOSE:
The purpose of this document is to define the BCVS acceptance level of die castings
intended for production use and to serve as an aid to the casting suppliers.
3.0 REFERENCED DOCUMENTS:
3.1 North American Die Casting Association, NADCA Product Specification

Standards.
3.2 BW-107-ES Date Code Requirements.
4.0 GENERAL:
4.1 In those cases where a special flatness is required, it will be specified on the
drawing. Otherwise NADCA Standards shall prevail.
4.2 Mastering surfaces will be specified on the casting drawing when required.
These are cast surfaces, which are used to locate the casting in a machining
fixture for first machining operations.
4.3 Die casters who intend to machine castings to obtain the specified as cast
dimensions must note this fact on their quotation sheet.
4.4 Key surfaces to be machined will be identified per Section 6.4 on both the
casting and machining drawings1. These machining drawings must be provided
to the die caster by SBM as part of the quotation process.
4.5 Unless otherwise noted on the drawing, measurements for concentricity,

perpendicularity, runout, length, etc. shall not include parting lines, gate marks
or flash.
1
This is provided as an aid to the die caster in understanding BCVS casting requirements, even though the
casting supplier may not be doing the machining
3 of 6
5.0 POROSITY:
Die castings are never entirely free of porosity. However, this standard will attempt to
define the degree of porosity and imperfections permitted based on the functional need
of both the “as cast” and “as machined” part as it pertains to their use in the BCVS
organization.
5.1 Definitions:
5.1.1 Porosity: Irregular shaped voids in the die cast part as a result of gas
bubbles, impurities, shrinkage, movement of base material, etc.
5.1.2 Pore Size: The size of the porosity is defined as the largest dimension
of the pore; i.e. major diameter of a spherical or irregular shaped void,
or the longest dimensions of a crack-like void. Typical descriptions
are “pin-point” which are pores .020” (0.5mm) diameter or smaller,
and “pit type” which are pores larger than .020” (0.5mm) diameter.
5.1.3 Surface Porosity: Surface porosity is defined as any void occurring at

a surface, either cast or machined.
5.1.4 Chain Porosity: Chain porosity is a set of interconnected pores

forming a chain-like void.
6.0 REQUIREMENTS:
6.1 Working Pressure: Castings used in pneumatic control valves are designed for a
working pressure of 150 psi and must withstand a proof test2 of 600 psi without
failure. BCVS reserves the right to test components on production line or
laboratory equipment using either finished components or assemblies.
6.2 Leakage: The casting must be free of porosity, which may cause external
leakage.
BCVS reserves the right to test components on production line or laboratory

equipment using either finished components or assemblies.
Leakage determined to stem from air passage through gates, parting lines,
casting skin or other areas created by the casting process3 will be grounds for
rejection.
2
Frequency of proof testing is determined by statistical process control. Consult BCVS quality or 6 sigma
departments for further details.
3
Casting Process is further defined as the three processes of casting, annealing and cool down used in the
creation of the part. Optimized gating, reduced air entrapment, fewer cold shuts, reduced porosity and
optimized shot profiles are some of the parameters that can be optimized through the use of computer
simulation. Source: www/magmasoft.com or equal.
4 of 6
6.3 Porosity Levels: The level of porosity permitted will be determined by BCVS
and more than one level may be specified on a part. The level of porosity for
unspecified areas will be covered by a note on the casting and machining
drawings.
6.4 Machined Surfaces:
6.4.1 Key machined surfaces will be designated on the casting and

machining drawings by using the symbol K-1 or K-2. These surfaces
must meet porosity LEVEL 1 or porosity LEVEL 2 requirements
respectively to a depth, which will allow machining to the finished
dimension. For interpretation of these porosity levels refer to
Manufacturing Acceptance Standard Engineering Die Cast
Specification BW-111-ES Supplement.
K-1: Machined surfaces shall not have pores larger than those in Level
1 or a frequency of pore occurrence greater than that of Level 1.
K-2: Machined Surfaces shall not have pores larger than those in
Level 2 or a frequency of pore occurrence greater than that of Level 2.
6.4.2 Porosity Greater in Excess Level 3: In some instances porosity in

excess of Level 3 will be exposed in a non-critical machined zone of a
casting. When it is determined by BCVS engineering that strength and
gas tightness are not compromised for the section in question, porosity
in excess of Level 3 will be acceptable. In addition, the porosity
requirement does not apply to those cross sectional areas of solid
material that are 1/8” or greater from all adjacent surfaces; for
example, material that could be cored away, if practical. Such
exceptions should be noted in an NCM and added to the drawing if
deemed appropriate by BCVS engineering.
6.5 Surface Condition as Cast:

“As Cast” sealing surfaces will be identified on the casting drawing by the
symbol S. No parting lines or die drag marks will be permitted on these
surfaces. The surface finish, whether as a result of surface porosity, die
checking or abrasive (blast) cleaning, shall not exceed 160 microinches.
Unless otherwise specified on the casting drawing, the condition of all cast
surfaces must meet North American Die Casting Association Standard NADCA
G-6-6-94 Class 1. Identifying marks on castings must be completely legible
following cleaning and deburring procedures. If questions occur as to legibility,
they should be directed to BCVS engineering or quality department.
5 of 6
6.6 Flash4 Control:
Unless otherwise specified, the following requirements must be met:
6.6.1 Parting Line/External Profile Flash must be within 0.4 mm (.015”) of

the die casting surface (Ref: NADCA G-6-5-94).
6.6.2 Cored Hole and Insert Flash must be within 0.25 mm (.010”) of the die
cast surface (Ref: NADCA G-6-5-94).
6.6.3 Ejector Pin Flash must not exceed 0.60 mm (0.025”) height.
6.6.4 Removal of Flash at the Bottom of a Cored Hole: A 0.8 mm (.030”)

breakout around a trimmed hole is permitted.
6.6.5 Flash from Gates and Overflows: Thick gates and overflows; trim
flash must be 1.6 mm (0.060”). Thin gates; flash must be 0.8 mm
(.030”). Exceptions to this must be by approval between BCVS and
the supplier (Ref: NADCA G-6-5-94).
6.7 Ejector Pins:
6.7.1 The location and size of ejector pins will be mutually agreed upon by
BCVS engineering and the supplier.
6.7.2 Ejector pin marks may be raised or depressed 0.4 mm maximum
(.015”) (Ref: NADCA G-6-4-94).
6.8 Cracks:
Cracks which result from die trimming, part ejection, shrinkage, etc will not be
accepted.
6.9 Burrs and Sharp Edges:

Burrs and sharp edges created by machining process will be removed prior to
production use of the part, leaving a 0.08/0.38 mm (.003”/.015” break on
affected edge.
6.10 Date Codes:

Casting date code will comply with BW-107-ES.
4
Flash is defined as any excess cast metal the fills the voids created from improper die closure or die cavity
profile. It represents extra cost in the form of lost die casting pressure, extra metal, increased machining scrap
and potential operator harm among others. “ If you cannot take the time to correct the issue, then you cannot
afford to run the die” re: www/drdiecast.com
6 of 6
10. Material, Performance Test Results
• Actual results of testing are to be documented including metallurgical, chemical,

and physical testing and included in the PPAP package.
• The supplier’s material sub-contractor, testing date, and test lab used are to be
included on the test results sheet.
• Note that prior BCVS Engineering approval is required for some BW specs.
As an example, reference the Bendix spec, BW-104-P included in this document.
Material Test Results shall indicate and include:
• Design Record change level of the parts tested.

• Any authorized engineering change documents that have not yet been
incorporated in the design record.
• The number, date, and change level of the specifications to which the part was
tested;
• The date on which the testing took place;
• The quantity tested;
• The actual results;
• The material supplier’s name and, when required by Bendix, the assigned
supplier/vendor code.
NOTE: Material Test Results shall be presented as in Appendix D (PPAP 4th

Edition)
Performance Test Results must also include all of the above information.
Test results shall be presented as shown in Appendix E (PPAP 4th Edition)

11. Initial Process Study:
• Initial process studies are required where Bendix Special Characteristics are
applicable.
See Bendix procedures QR-0010 and DPP 6.2.2.2 in this section.
• The intent is for the supplier to show that they are producing product utilizing
process control. In addition to any BCVS Special Characteristics, supplier
should demonstrate process control by using any other product or process
characteristic that the supplier deems to be appropriate.
• The supplier shall perform measurement system analysis (see section 8) in order
to understand how measurement error affects the study measurements.
NOTE 1: Bendix reserves the right to require demonstration of initial process

capability requirements on any/all characteristics.
NOTE 2: Attribute data are NOT acceptable for PPAP submissions unless
approved by an authorized Bendix representative.
NOTE 3: Bendix requirements for Cpk and/or Ppk are outlined in Bendix
procedure QR-0010 and DPP 6.2.2.2. See AIAG (2nd Edition) reference manual for
SPC applications.
NOTE 4: Initial Process Studies (even for short term) are to be conducted using
process control charts in order to collect and analyze the data.
NOTE 5: Short term studies should be based on a minimum of 25 subgroups

containing at least 100 readings from consecutive parts of the production run.
Other analytical analysis must have prior approval from an authorized Bendix
representative.
• Bendix acceptance criteria for initial studies is outlined in QR-0010 and DPP
6.2.2.2
• The supplier shall notify Bendix representatives of any unstable process that
exists and submit a corrective action plan PRIOR to any PPAP submission.
• Acceptance criteria for processes with one-sided specifications or non-normal
distributions need to be approved by an authorized Bendix representative.
• IF acceptance criteria can NOT be met by PPAP submission date, a corrective
action plan and modified Control Plan providing for 100% inspection shall be
submitted to the authorized Bendix representative. See Bendix Requirements
in QR0010 sections 4.2 and 4.3.
Elyria, Ohio
PROCEDURE TITLE: DEPARTMENT: Quality Assurance
Bendix Special Characteristics PROCEDURE: QR-0010
REVISION: 16
ISSUE DATE: January 9, 2009
PAGE: 1 of 4
Cover Sheet
DISTRIBUTION:
Acuña/Del Rio - Quality Manager (Hard Copy)
Bowling Green - Quality Manager (Hard Copy)
Huntington - Quality Manager (Hard Copy)
Engineering - Leadership Team (L.A.N. Copy)
Supply Base - Director (L.A.N. Copy)
SQD - Manager (L.A.N Copy)
Revision History Table

REVISION # Org. 13 14 15 16
WRITTEN BY H. Bruewer J. Sims J. Sims J. Sims E. Smith
APPROVED BY H. Bruewer R. R. Dominguez M. Goetz M Goetz
Dominguez
ISSUE DATE October 27, 1988 11/15/2006 9/5/07 7/9/08 1/9/09
APPROVAL
SIGNATURE
Approve UPDATED Approve QR-0010
ISO QR 0010.msg
Bendix Special Chara
Please note: Revised text is in italics and also underlined
Revision 16:
Distribution section removed Frankfort and replaced with Bowling Green.
Added Table of Contents to page 2
Added DPP 6.2.2.2 – Identification and Treatment of Special Characteristics as a specific reference for this
procedure.
This copy was printed on 1/7/2009. Warning: The user must verify it is the current revision prior to use.
Elyria, Ohio
REVISION: 16
PAGE: 2 of 4
The information contained in this document is the property of Bendix Commercial Vehicle Systems.
Table of Contents:
1.0 Previous Special (Classified) Characteristics

2.0 Restrictions
2.1 Fan Drive Exception
3.0 Concessions for Non-Conforming Material (NCM)
3.1 No concessions for Star, Shield, Diamond
3.2 Concessions for Circle c/c characteristics
4.0 Control
4.1 Short-term capability
4.2 Non-Conformance to capability requirements
4.3 Written Plan for improving capability
4.4 Control method as detailed in Control Plan for Special Characteristics (See DPP 6.2.2.2)
4.5 Capability requirements for Circle c/c Characteristics
5.0 Original Definitions – Shield, Star, Delta
Elyria, Ohio
REVISION: 16
PAGE: 3 of 4
1.0 Previous Special (Classified) Characteristics

This document obsoletes the Star, Shield, and Delta Classified Characteristics. These characteristics are still valid
for existing drawings, but they cannot be used on new or revised drawings after release of this document. These
characteristics must be replaced with the new S/C or C/C symbol when a drawing is updated. The circle c/c
(obsolete from a previous revision) must either be updated to a new symbol or removed.
2.0 Restrictions
2.1 Fan Drive Exception: This procedure is not applicable for Fan Drive components / assemblies and assembly
processes. Special (Classified) Characteristics assigned to the fan drive drawings were based on other criteria, not
driven by DFMEA. Therefore, the Special Characteristics assigned to fan drive component / assemblies and
processes are not valid nor covered by this document.
3.0 Concessions for Non-Conforming Material (NCM)
3.1 No concessions are allowed for Star, Shield, and Delta symbols.
3.2 Concessions are allowed for circle c/c only with signed approval from the Product Engineer and the Customer
(if applicable).
4.0 Control
4.1 All Star, Shield, and Delta symbols are to be produced on a process with a minimum short-term capability of
1.67 Cpk (±6 Sigma). The long-term capability of the process must be monitored and maintain a 1.33 Ppk
minimum.
4.2 All characteristics not meeting capability requirements must be checked 100% on a device (test stand or
inspection equipment) that is free from operator interpretation.
4.3 Any Special Characteristic that does not meet capability must have a written plan for improved capability
established and approved by the Plant Quality Manager.
4.4 The control method must be detailed in the control plan for all Special Characteristics. Specific controls are
detailed in Procedure DPP 6.2.2.2. The required sample size will follow the latest edition of AIAG PPAP manual or
as agreed upon in the control plan.
4.5 Circle c/c characteristics still on drawings must have an initial short term capability Cpk of 1.33. It is not
necessary to track long term capability.
5.0 Original Definitions
Shield: This characteristic is typically associated with requirements under

applicable regulation or legislation.
Star: This characteristic is typically associated with a Severity Rating of 9 or 10

n the Design FMEA. Assigning a star characteristic to the drawing requires
prior approval of the Product Integrity Committee (PIC).
Elyria, Ohio
REVISION: 16
PAGE: 4 of 4
▲ Delta: This characteristic is typically associated with a Severity Rating of 8 in

the Design FMEA.
12. Qualified Laboratory Documentation:
• The supplier shall have Inspection and Testing for PPAP (as well as regular
production) performed by a qualified laboratory as defined by customer
requirements. (e.g. an accredited laboratory)
• The supplier’s qualified laboratory (internal or external) shall have a laboratory

scope and documentation showing that the laboratory is qualified for the type of
measurements or tests being conducted.
• Supplier shall submit test results on the laboratory letterhead or the normal
laboratory report format when an outside laboratory is used. The following
information must be included on the report:
• Name of the laboratory that performed the tests.
• The date(s) of the tests.
• The standard(s) used to run the tests shall be identified.

13. Appearance Approval Report:
• The AIAG format is to be used.

• A separate AAR must be completed for each Bendix part number unless
otherwise agreed to by the part approval activity of the using facility.
• An AAR is required for each part for which a submission is required if the
product/part has appearance requirements on the design record. When in doubt,
contact the using plant quality function.
NOTE 1: AAR typically applies only for parts with color, grain, or surface
appearance requirements.
NOTE 2: Certain customers may not require entries in all AAR fields. See Appendix
B (PPAP 4th Edition) or customer-specifics for detailed instructions on completing the
AAR.
14. Sample Product:
• Unless otherwise specified by the using plant approval activity, the supplier shall
submit 3 samples with the PPAP. If production parts will be produced from more
than one cavity, mold, tool, die, pattern, or production process, e.g. line or cell,
then the supplier shall submit one sample for each position of a multiple cavity
die, mold, tool or pattern, or production process. Such samples shall be
appropriately identified.
15. Master Sample:
• Unless otherwise specified by the using plant approval activity, the supplier shall
retain master samples per AIAG PPAP requirement. See AIAG (PPAP 4th
Edition) section 2.2.15 on Master Sample retention.
• If production parts will be produced from more than one cavity, mold, tool, die,
pattern, or production process, e.g. line or cell, then the supplier shall retain one
sample for each position of a multiple cavity die, mold, tool or pattern, or
production process.
16. Checking Aids:
• It is a recommended best practice for the supplier to submit digital pictures of

checking aids such as fixtures, models, gages, templates, mylars etc. Pictures
should show the checking aid itself, and how it is used with the part being
evaluated.
• If required by Bendix, supplier shall submit with the PPAP submission any part-
specific assembly, component checking aid, or the design/purchase source of
same.
• Supplier shall certify that all aspects of the checking aid agree with part
dimensional requirements.
• Supplier shall provide for preventive maintenance/calibration of any checking aids

in their possession for the life of the part.
• Measurement systems analysis studies shall be conducted in compliance with

Bendix requirements. (See MSA AIAG manual – 3rd Edition)
17. Records of Compliance With Customer Specific Requirements - BCVS

Specific:
• Conformance to QR0010, BCVS Special Characteristics.
Reference QR-0010 and DPP 6.2.2.2 at element # 11, "Initial Process Study".
• Labeling requirements Ref BW-5348, and packaging requirements, Ref BW-5347.
Reference the Bendix procedures BW-5348 and BW-5347 included in the BCVS
Business Manual.
• Supplier should submit samples of labels, and pictures or sketches of packaging.
• The supplier shall have records of compliance to all applicable Bendix-specific

requirements.
18. Part Submission Warrant:
• The AIAG Part Submission Warrant (North American Truck Industry or

Automotive) must be used. See AIAG/PPAP Manual – 4th Edition.
• All fields listed on PSW must be addressed. Information must be inserted in each
cell.
• A separate PSW must be completed for each Bendix part number unless
otherwise agreed to by the part approval activity of the using facility.
• Unless otherwise specified by the Bendix using facility, use the instructions in the
AIAG PPAP Manual – 4th Edition, for filling out the Part Submission Warrant.
19. Supplier Change Notification and Submission Requirements:
• Suppliers shall notify the authorized Bendix representative (via sqd@bendix.com)

of any planned changes to the Product Design, Process, or Site of manufacture.
• See Table in AIAG PPAP Manual – 4th Edition, for examples of changes requiring
notification and approval by Bendix.
• IF Change Notification is required, Supplier shall use the PRODUCT/PROCESS

CHANGE NOTIFICATION FORM in the Bendix Supplier Business Manual or on
the Bendix Internet Site at www.Bendix.com. Complete form as per instructions.
• Submit PPCN form to your authorized Bendix representative BEFORE

SUBMITTING PPAP TO THE USING PLANT . Wait for Bendix approval
BEFORE proceeding with the requested change.
• PPAP Submission is required unless otherwise specified.

PPAP ACRONYMS FOR BENDIX PPAP MANUAL – 1ST REVISION
AAR – Appearance Approval Report

AIAG – Automotive Industry Action Group
APQP – Advanced Product Quality Planning
ASTM – American Society for Testing Materials
BCVS – Bendix Commercial Vehicle Systems
BW – 11 1 – ES Bendix Westinghouse – 111 – Engineering Standard
C/C – Critical Characteristic
CMM – Coordinate Measuring Machine
Cpk – Long Term Capability
DFMEA – Design Failure Mode and Effects Analysis
DPP 6.2.2.2 – Detail Process Procedure 6.2.2.2
ECL – Engineering Change Level
ECN – Engineering Change Notice
FMEA – Failure Modes and Effects Analysis
Gage R & R – Gage Repeatability and Reproducibility
ISO – International Standards Organization
LLC – Limited Liability Company
MCR – Material Concession Request
MSA – Measurement Systems Analysis
NCM – Non Conforming Material
PPAP – Production Part Approval Process
PpK – Short Term Capability
PSW – Part Submission Warrant
QR – 0010 - Quality Requirement 0010
RPN – Risk Priority Number
S/C – Significant Characteristic
SBM – Supply Base Management

2009 Bendix Ppap Requirements Guidelines Rev 1-9-2009

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Bendix Commercial Vehicle Systems LLC

Supplier Quality and Development

Bendix Production Part Approval Process

2009 Bendix Requirements Guideline

REVISION HISTORY TABLE

The 2009 Bendix Requirements Guideline for PPAPs is based Automotive

Recommended A.I.A.G. Reference Manuals for this Document include:

Advanced Product Quality Planning & Control Plan - APQP – Second

Potential Failure Mode and Effects Analysis – FMEA – Fourth Edition

Measurement Systems Analysis – MSA – Third Edition

Statistical Process Control – SPC – Second Edition

A.I.A.G. manuals are available through www.aiag.org

Production Part Approval Process (PPAP)

Bendix Requirements Guideline (PPAP 4th Edition)

2. Authorized Engineering Change Documents

3. Customer Engineering approval

4. Design FMEA (Failure Mode and Effects Analysis)

5. Process Flow Diagram(s)

6. Process FMEA (Failure Mode and Effects Analysis)

8. Measurement System Analysis Studies

10. Records of Material / Performance Test Results

11. Initial Process Studies

12. Qualified Laboratory Documentation

13. Appearance Approval Report (AAR)

14. Sample Production Parts

15. Master Sample

16. Checking Aids

17. Customer-Specific Requirements

18. Part Submission Warrant (PSW)

19. Supplier Change Notification and Submission Requirements for PPAP

Production Part Approval Process (PPAP)

Bendix Requirements Guideline

There are currently 19 elements that are the requirements of PPAP.

• All 19 requirements are to be addressed, regardless of level of submission.

• Page 1 of the PPAP Submission Package is recommended to be an

• Production part approval records, regardless of submission level shall be

• All Drawings, Specs, and other supplemental information contained herein

Production Part Approval Process (PPAP)

• Reporting of Part Material Composition shall be provided by the supplier when

Production Part Approval Process (PPAP)

2. Authorized Engineering Change Documents:

• Examples include marked up drawings signed and approved by BCVS

Production Part Approval Process (PPAP)

Bendix Requirements Guideline

3. Customer Engineering Approval:

As an example, reference the Bendix spec, BW-128-P, section 6.0 included in

PROCESS SPECIFICATION BW-128-P

CHROMATE CHEMICAL CONVERSION FILM (ALODIZING)

The purpose of this process is to produce a chemical chromate conversion film on

3.2 If the conversion coating bath is heated, stirring is recommended to avoid

Ralph Lennerth 12/10/99 Dave Knight 12/10/99

REVISED SPEC. BW-128-P

PROCESS SPECIFICATION BW-128-P

CHROMATE CHEMICAL CONVERSION FILM (ALODIZING)

Operation Solution Concentration Temperature Time

** Alodine 1600 is a product of Henkle Corporation.

Alchrome #2 Alchrome #16 LX-1104/LX-1105

A stainless steel or Koroseal lined tank is required.

3.4 Casting Impregnated per BW-108-P

PROCESS SPECIFICATION BW-128-P

CHROMATE CHEMICAL CONVERSION FILM (ALODIZING)

3.5 Maintenance of Solutions

Individual manufacturer’s procedures shall be used to prepare and maintain