PLASTIC FUEL TANK HOT PLATE WELDING

MINIMUM PROCESS REQUIREMENTS CHECK SHEET

QAV Date:
Supplier Name: LEGEND: Procedure followed. Hard/Soft-side item functioning. OK for MP.

Parts Evaluated: . Procedure utilized, but improved compliance required. Low risk to MP
Project: X Procedure not followed. Immediate countermeasure required, must fix for MP.

Check Method JUDGMENT

Is this
controlled in
current X
.
process Y/N
1 Receiving Inspection Item Suggestion Method of control Frequency Comments
Supplier must have a documented system to
confirm type of material (resin) received and
identify and confirm critical properties
(including melt flow index) of incoming raw
1 Material Confirmation
materials. Test sample(s) must be taken by
Each material lot.
molding/welding supplier directly from resin
shipping container. Records of review and
confirmation are to be kept.

Complies with Traceability and Lot Control

requirements as defined in the Honda
Supplier Quality Manual. (All through-hole
2 Traceability welded components are to be treated as Each material lot.
range to range as described in Traceability
and Lot Control section of Honda Supplier
Quality Manual).

Check Method Is this JUDGMENT

controlled in
current
process Y/N .
X
2 Equipment Item Suggestion Method of control Frequency Comments

Critical parameter set points to be

established and listed on PQCT and subject
to IPPAAR approval for changes. Critical
parameters to include, at a minimum: hot
Time, temperature, and pressure Start of shift or
1 control settings
plate temperature; matching time; matching
product change.
pressure; heating time; heating pressure;
change-over time; joining (fusion) pressure;
and cooling time. Must be verified and
recorded through operator check.

The critical parameters (listed above) must

be automatically monitored. Critical
temperatures must be monitored by
redundant thermocouples. If any critical
2 Fail-safes time, temperature, or pressure is detected 100%
outside of specified range(s), equipment
must stop processing and, unless otherwise
agreed to by Honda, positively destruct
abnormal part.
Must have lockout to prevent unauthorized
3 Equipment Adjustments
adjustment of machine conditions.
100%

Check Method JUDGMENT

Is this
controlled in
current X
.
process Y/N
3 Process Controls Item Suggestion Method of control Frequency Comments
Flatness requirement to be specified on
Flatness of mating area on main
1 body (e.g., fuel tank shell)
PQCT and automatically monitored and 100%
recorded.
Component part positioning Controlled during all phases of welding
2 (including perpendicularity/ process. Method of control to be agreed 100%
parallelism/angularity) upon with Honda.

Must be able to provide quantifiable/variable

Component part positioning and
3 flatness capability
data and/or trends that confirm current Upon Request.
production conforms to all specifications.

The finished product is to be uniquely

identified (i.e. serial numbered), and the
base part molding cavity, weld fixture, and
4 Process fixture identification cooling fixture identification are to be 100%
traceable for each finished product (only
cavities and fixtures potentially affecting
critical weld(s) need to be traceable).

Base parts and components to be welded

must come to and remain at process line
ambient temperature prior to welding.
Dimensional stability (prior to
5 welding)
Minimum time to achieve ambient 100%
temperature to be determined during new
model development and agreed upon with
Honda.
All process parameters must be controlled to
prevent thermal decomposition of welded
6 Thermal decomposition
materials. Critical temperatures to be
100%
monitored by redundant thermocouples.
Hot plate/component part head travel
distance must be controlled by linear
7 Head travel distance
potentiometer or LVDT (Linear Variable
100%
Displacement Transducer).
Must be kept free of contamination (e.g.
8 Hot plate heating surface condition grease, decomposed plastic, etc.) and in 100%
good condition.

Check Method JUDGMENT

Is this
controlled in
current
process Y/N . X
4 In Process Inspection Item Suggestion Method of control Frequency Comments
Weld integrity is to be confirmed by visual
check for ‘double bead’ and leak check of a
type and duration to be agreed upon with
1 Weld integrity
Honda. A method must be used to show
100% or as required.
successful completion of checks and shown
on part (by marking) or tied to serial number.

Note: Quality confirmation check items are to be verified by an associate independent of

the production process. Check Method Is this JUDGMENT
controlled in
current
process Y/N .
X
5 Quality Confirmation Item Suggestion Method of control Frequency Comments
Must use Microtome analysis to confirm melt
depth, melt thickness, and displacement Each set up or
with control limits to be agreed upon with changeover and,
1 Weld quality Honda. Must be able to demonstrate weld additionally, as
process consistently meets control limits. agreed upon with
Microtome data to be analyzed over time for Honda.
trends.

Microtome analysis to be done on all critical

welds. Measurement method to be Each set up or
established with Honda, however, a changeover and,
2 Weld quality minimum of four samples with 90 degree additionally, as
separation between each is required; agreed upon with
‘averaging’ of data not allowed. Microtome Honda.
slides to be retained 6 years.
Whole component pull test. Main body or
component part to fail before weld. Pull
Start of each shift
force data to be recorded and tracked for
3 Weld quality
trend analysis. Pull force lower control limits
and at each other first
piece confirmation.
to be established with Honda during new
model development.
Pry/flower/fan test (cross sectional tensile
Start of each shift
and bend tests). A minimum of eight cuts
4 Weld quality
with 45 degree separation between each is
and at each other first
piece confirmation.
required.
Confirm by destructive test (pin/microtome)
and visual inspection. Component part
Component part concentricity to original footprint must be 100% located on Start of each shift
5 applicable feature (e.g. bored main body original footprint (melt pad and at each other first
hole) on mating part extended bead is not considered part of piece confirmation.
original footprint for either component part or
main body). See diagram 1.

Component

Melt Pad

Main Body

Extended bead

Diagram 1

HSQM-0074 Page 1 of 1 03/12/09