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GM Engineering Requests & Info for Fabric


Engineering Requirements & Information for Seat Fabric
Supplier should implement lessons learned from experience with other OEM’s. ? Supplier should not let GMDAT select products sup

plier does not believe in (feasibility etc.) ? Supplier is responsible for actively tracking the schedule towards project timing. ? Supplier is responsible to evaluate and announce possible weakness of the product. ? Supplier is responsible to clearly communicate all changes with GMDAT, pre and after Start of Production. (i.e. quality, timing, production location, yarn changes, etc.) 1.1.12.2 The fabric development and approval should be done with the material from the production site and production condition. If production site and/or production condition is changed after approval, supplier would be charged for re-development. ? During the appearance and construction approval, GMDAT will request the fabrics for parts validation. ? After appearance and construction approval, GMDAT will require the fabrics for parts validation test. Supplier should supply the fabric within the schedule. ? Fabric supplier should communicate with Tier1 supplier for parts validation and processability of the parts. If some changes on the fabric are requested to improve parts application, fabric supplier should immediately report it to GMDAT engineering. ? If some changes by supplier without reporting, it could be a reason to reject the production supplier and also will affect the business for the next program. ? Fabric supplier should submit the master sample after fabric approval. The master sample should be prepared in production condition. The requirement for master sample will be given to the supplier. 1.1.13 The fabric supplier should supply fabric for fabric approval test, build for parts validation test and build for Proto & Pilot vehicle without any problem. 1.1.14 Quotations shall be submitted in U.S. dollars and on a square meter basis ($/m2). 1.1.15 All fabric prices shall include lamination foam with polyethylene film or scrim 1.1.16 All fabric quotations shall be documented on the GM cost breakdown form (GM1804) as well as the long-term agreement form. (3, 3, 3 is the minimum). Quotes should include proposed manufacturing location. Quote FOB, your facility.
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1 Scope The Engineering Requirements & Information (ENGRG Req’t & Info) for Seat Fabric is an outline of the fabric selection process. This document can be referenced and used as a general guide. 1.1 Engineering Guidelines (For new and existing suppliers) 1.1.1 Suppliers shall be on the General Motors Bidder list. 1.1.2 Quality audits shall be completed at the manufacturing facility. 1.1.3 All documents should be submitted in English. 1.1.4 A company overview including organizational charts and joint ventures shall be submitted. 1.1.5 An explanation of the manufacturing process, incoming inspections, and quality inspections shall be submitted to Engineering. 1.1.6 Before quoting, a supplier shall list their capability. An equipment list is also necessary. For example: Capability equals tricots, circular knits, and specialty products. Capacity equals 14 double needle bar machines. 1.1.7 Lab Accreditation. Lab testing shall be performed by a laboratory that conforms to ISO/IEC 17025 or ISO 9001 or other 3rd party accreditation and is acceptable to the GM Materials Engineer. Supplier shall submit documentation showing proof of accreditation. 1.1.8 All suppliers shall participate in design and supplier gate reviews. 1.1.9 All designs are GM confidential. These designs are to be exclusively used for design, engineering, and purchasing purposes. 1.1.10 Materials shall meet the requirements of the automotive upholstery fabric specification (GMW14231 - March 2008), otherwise described on the ‘ENGRG Req’t & Info’. Information Handling Services(IHS) has all rights reserved on external distribution of GM-standards Webaddress till IHS: http://global.ihs.com. Construction Certification Data Form can be found on http://www.gmsupplypower.com. 1.1.11 Selected suppliers will be invited to the design kick-off meetings. 1.1.12 Technical support shall be available for all technical reviews and risk assessments. 1.1.12.1 The product & design shall fulfill GMDAT requirements and satisfaction from start to end of life cycle. The suppliers have the responsibilities as below.

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

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Engineering Requirements & Information for Seat&Doortrim Fabric
1.1.17 Volumes for quotes are model year estimates only. These volumes are subject to change (volume estimates are not a firm commitment from GM). 1.1.18 If it is treated the soil repellent on fabric, supplier shall submit the information of soil repellent that are material, method, process and any of technical information that is related the material construction and quality. The program will be determined if a soil repellent will be needed based on program colors. 1.1.19 Fabric suppliers are “vendor of record” for the fabric and foam composite. Cost is FOB the fabric suppliers’ facility. 1.1.19.1 The foam used in any laminate construction shall meet the requirements of GMW15058. The supplier shall provide information including test report that meet material requirement. Information Handling Services (IHS) has all rights reserved on external distribution of GM-standards Web-address till IHS: http://global.ihs.com. 1.1.20 The Pattern direction of fabric design for Trim Cover(of Seat, Doortrim, Instrument Panel, etc.) shall be confirmed by Design(Color&Trim Team) during Technical Review. And it shall be reflected in the fabric quantity to make trim cover. If necessary, fabric supplier should have support from Tier-1 to make a part, and then appearance shall be confirmed by Design(Color&Trim Team) in condition of assembly part. 2 Reference Only the latest approved standards are applicable unless otherwise noted. Documents can be obtained through the GMDAT Appearance Material Engineering. Contact: sunyoung.ahn@gmdat.com (82-32-520-4395) 3 General Information 3.1 Critical Milestones 3.1.1 Program Timing 3.1.2 Seat Suppression 3.1.3 PPAP 3.1.4 Full Color Approval 3.1.5 Full Construction Approval 3.1.6 Seat Builds and Appearance Reviews 3.1.7 Cut & Sew Evaluation 3.1.8 Color & Trim Gate Reviews (1-3) 3.1.9 Technical Reviews (samples required) 3.1.10 Advanced Design Reviews (on-going) 3.1.11 Deadlines for Quotes 3.2 Functional Work Groups Involved 3.2.1 Marketing (VSSM) 3.2.2 Design Studio (DES: Color & Trim Team) 3.2.3 Program Team (PET) 3.2.4 Global Purchasing Supply Chain (GPSC) 3.2.5 Supplier Quality Engineering (SQE) 3.2.6 Cooperative Tier 1 3.2.7 Color & Trim Studio(C&T: Color & Trim Team) 3.2.8 Fabric Suppliers (FS) 3.2.9 Program Vehicle System Engineer (VSE) 3.2.10 Seat Engineering (SE) 3.2.11 Materials Engineering (ME: Polymer / Organic Material Lab Team) 3.2.12 Appearance Material Engineering (AME: Appearance Material Engineering Team) 3.2.13 Suppression Engineering (SE: Safety System Integration Team, Airbag Sensing Performance) 3.2.14 Program Planning 3.2.15 Engineering Finance (Design Cost Analysis Team) 3.2.16 Design Appearance Quality (DAQ) 4 Fabric Technologies 4.1 The fabric shall pass the requirement of the assembly parts and suppression validation. e.g. Seat, SBR, OC Sensor, etc 4.2 The fabric shall be capable of meeting the build and quality standards for assembly processes. 4.3 The fabric shall meet Color & Trim Design Requirements. 4.4 The genuine leather shall meet the government requirement. e.g. Flammability of Interior Materials – FMVSS/CMVSS302[North America], GB8410[China], Article95(KMVSS302) – Test without support wire [Korea], GSO98[G.C.C] - etc 4.5 Fabrics of a flat construction i.e. no pile surface, are required to have a soil repellent finish if the L* measurement for color value is higher than 31.0 (as measured on the plastic primary color master). The soil repellent shall be treated for all seat fabrics. The soil repellent finished fabric shall meet the requirements of the automotive upholstery fabric specification (GMW14231) Supplier shall submit the information of soil repellent type (Standard Treatment, Premium Treatment) to GM. The detail information of soil repellent treatment shall be described on the Textile Construction Specification Sheet. 4.6 If any, Specific Finish Treatment(Soil repellent, Anti-static treatment or etc.) shall be informed to GM using Textile Construction Specification Sheet. 5. Specification Development

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

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Engineering Requirements & Information for Seat&Doortrim Fabric
Shall meet the req’t GMW14231(March 2008). All of requirements in ‘ENGRG Req’t & Info’ have priority over requirements of ‘GMW14231’. Note: For requirements for vehicles without solar absorbing glass, contact the appropriate Materials Engineer. All interior materials are developed to be used in vehicles with solar glass. Therefore performance may be compromised if used in nonsolar glass vehicles 5.1 Material Construction Specification Test for initial approval may be done on face fabric or as a composite such as a foam laminate. For initial approval of foam laminated seating and door fabrics, the thinnest foam used in production, usually 3 mm, shall be tested. Initial construction submissions shall be in a light value color with an L* value of 55.0 or higher and with soil repellent treatment. All required information shall be reported on the construction certification Data form (Appendix A in GMW14231). If all individual readings of a specific test meet or exceed the specified requirements, report the average. The Lab Package, which is required submission on GMW14231, shall be submitted with Construction Certification Data Form. A form shall be submitted along with each fabric and fabric composite for engineering approval. Established values for a construction will be reported on and controlled within the limits established on the construction specification form. 5.1.1 Width – Acceptable production tolerance between selvages will be 0 or ± 50 mm of the width defined on the construction specification. List the minimum and maximum width and confirm the width with Purchasing. 5.1.2 Seam Fatigue (GMW3405) – The used needle type for test shall be noted in the report. 5.1.3 Resistance to Wear/Abrasion See ‘Resistance to Wear/Abrasion’ table, to test fabrics for wear. Three samples are to be tested (right side, center, and left side), and show each direction on sample. 5.1.3.1 Taber Method (GMW3208) 5.1.3.2 Martindale Method (ISO12947-Part I, II and IV) 5.1.3.3 Schopper Method (GMW3283) – Test 2 specimens using a 1,000g weight for 200 cycles (weight loss). The maximum weight loss 2 requirement is 5g/m after 200 cycles. No holes (one thread break) after 1,000 cycles. 5.1.4 Pilling Resistance (EDS-T-7699) 5.1.5 Snagging Resistance 5.1.5.1 Rivet Method (GMW14775) Applicable for fabrics with long floats, generally > 2mm floats, at the discretion of the GM engineer, Test in the MD, CMD, bias left and bias right directions. The requirement is no snagging or catching of the float by the rivet, in all directions and angles of test. 5.1.5.2 Mace Method – Test 1 specimen for each direction: MD and CMD. The min. rating 3 is required after 600 cycles under 60 rpm using ICI type Mace tester. 5.1.6 Soil & Cleaner Resistance (GMW3402, Part A & B) – For Soil Repellent finished Flat Fabric, Requirement for Soil & Cleaner Resistance shall meet the Section 3.5 in GMW14231 (Soil Repellent Requirement) Procedure - A is changed. Please refer to below. - Test all soiling agent except for Code E. Code K and L are for information only. Specimens tested per procedure A are to have a Delta L Value of 55 or greater, and additionally submit test result with medium Delta L value(32 ~54) color for reference. 5.1.7 Stretch&Set(GMW3211) – Test three specimens each direction: MD, CMD and Bias. Report the average for each direction. For MD and CMD, the maximum allowable stretch is 25%; the maximum allowable set is ≤ 4%. For Bias, report the value for information. 5.1.8 Sag Resistance(GMW3214) – Report the value for information. - As received: follow GMW3214 - After aging: 60°C x 24h then follow the test procedure. The following procedure should be performed in the chamber(60°C x 24h) 5.1.8.1 The test specimen shall be placed on the annular base plate and securely tightened by the clamping ring, ensuring that the surface is smooth, flat and free from stress. 5.1.8.2 The top plate of the clamping device shall be tightly screwed onto the platform of the test equipment to a torque strength of (7...8) Nm. For laminated materials the clamping ring may be omitted. Such test specimens shall be securely tightened only by means of the top plate. 5.1.8.3 The indentor and rod shall be gradually lowered until a pre-force (F0) of (1.5 ± 0.1) N is applied to the test specimen. That pre-force shall be held for (10 ± 1) seconds, then the vernier scale shall be zeroed. 5.1.8.4 The total test force (F) of (50 ± 5) N (which equals F0 + force exerted by any additional weights F1) shall be applied for (60 ± 1) minutes. The following procedure should be performed at room temperature. 5.1.8.5 All forces shall be removed and the test specimen allowed to recover for (60 ± 1) minutes.

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

Page 3 of 6

Engineering Requirements & Information for Seat&Doortrim Fabric
5.1.8.6 The pre-force F0 shall be re-applied and the resulting depth of penetration recorded after (10 ± 1) seconds. 5.2 Color requirement Test for the color requirement to be completed for each fabric color once the initial construction has been approved. Test for initial approval may be done on a fabric material or on a fabric composite following the initial construction approval. All construction requirements are expected to match the initial construction approval even though properties of color requirement are not all retested for each color. Evaluate per ISO 105-A01. 5.2.1 Soil & Cleaner Resistance (GMW3402, Part A & B) – For Soil Repellent finished Flat Fabric, Requirement for Soil & Cleaner Resistance shall meet the Section 3.5 in GMW 14231 (Soil Repellent Requirement) 5.3. Laminate Requirements Test for the laminate requirement to be completed for fabric laminates after initial construction approval has been achieved. This section applies primarily to foam thickness changes unless otherwise directed by the approving engineer. Testing shall be conducted on a production color. If the foam type, foam supplier/location or scrim, change, then perform Section 3.2 in GMW 14231 in its entirety. Note: Initial approval of foam laminated seating and door fabrics, is conducted using the thinnest foam used in production, usually 3 mm. (See Section 3.2 in GMW14231). Note: This section applies to seating and door fabric laminates only. For all other fabric laminates, perform Section 3.2 in GMW 14231 in its entirety. 5.3.1 Foam Requirements. The foam used in any laminate construction must meet the requirements of GMW15058. The supplier shall provide documentation of foam approval. If GM requires, supplier shall submit Construction Certification Data Form and same lot of samples that supplier tested for the test by GM. 5.4 Soil Repellent Requirements This section describes the additional requirements for soil repellent treated seating fabrics. These tests are to be performed at the time of construction approval. Fabrics of a flat construction i.e. no pile surface, are required to have a soil repellent finish if the L* measurement for color value is higher than 31.0 (as measured on the plastic primary color master). Requirements are different depending on the type of finish used as defined below. It is expected that all soil repellent finishes are as durable as the fabric to which they are applied and effective for 10 years’ service life. Note: Fabrics not treated with a soil repellent finish, including dark color flat fabrics which are exempt from treatment per the Best Practice #112003, should not be expected to meet all of these requirements, including water repellency, oil repellency and surface energy. 5.4.1 Fluorocarbon Water Repellent Treated Fabrics (Standard Treatment). 5.4.2 Combination Treatment (Premium Treatment). For fabrics treated with soil repellent/release, antimicrobial and anti-static combination finishes. 6. Additional Requirements. 6.1 Cut, Sew and Processability. Fabric supplier provides Seat supplier(Tier-1) with the fabric sample in production intention and evaluates cut&sew processability. After Tier-1 sign-off, fabric source submits the evaluation result using Fabric Processability Evaluation Form(see Appendix) to GM engineering. If any changes of fabric are required for the processability, fabric source shall inform the changes to GM design and engineering. When the changes will affect any design changes and/or any failure of GMW14231, the fabric would be rejected. 6.2 Part Performance (GMW14444). All fabrics covered by this specification are subject to part performance through part validation. 6.3 Roll Direction. To be specified by the material source and communicated to all purchasers. 6.4 Ingress/Egress/Jounce Seat Durability Performance (GMW14364) Testing per GM engineering validation requirements, no failures due to material performance are acceptable. 6.5 DFMEA analysis. If necessary, Fabric supplier should communicate with Tier-1 supplier to perform DFMEA. Supplier fulfils all required DFMEA analysis and submits the finalized DFMEA analysis in paper. 6.5.1 Fabric supplier shall submit the data to verify that there will be no potential quality issue (e.g. weak velcro, snagging and dirt resistance, etc.) after SORP. These test method is only for reference, not mandatory. If supplier tests with another method, supplier shall submit the information of material, method, process and any of technical information. 6.6 Backing Lamination Specification Development (Engineering Requirements for GMW15058 (Polyurethane Foam) – The lamination composites are PU Foam and scrim (Polyethylene film is acceptable for optional), which are laminated on the backside of the face fabric. The required lamination spec for seat covering shall meet the Fabric requirement specification from the Engineering. The supplier shall provide documentation of foam approval.

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

Page 4 of 6

Engineering Requirements & Information for Seat&Doortrim Fabric
7. Supporting Documentation: (See Fabric Material Approval Engineering Certification Package) 7.1 Access to GM Supply Power 7.2 Scope of Accreditation and Lab Certification 7.3 GMW3059 (Restricted and Reportable Substance Form) 7.4 Recycling Guidelines (GMW3116). Recycled content shall be reported to the approving and procuring Materials Engineering Department utilizing the Part Recyclability/Recoverability Report Form. Refer to Appendix A of GMW3116, Recyclability Recoverability Guidelines. 7.5 Process Flow Chart 7.6 Construction Certification Data Sheet (Appendix A in GMW14231) – All process changes shall be re-certified by the appropriate GM Engineer. 7.7 Material Safety Data Sheet (MSDS) 7.8 Monitoring Matrix Form (due the 15th of every month) 7.9 Sample for approval test (same lot of material as the lab package) – See ‘Seat Covering Material Quantity for approval test’ for detail. 7.10 Form for approval (Trim transmittal or Engineering Source Approval for Functional Performance sheet) – This form provided by GM is necessary to perform the PPAP. Submit the completed sheet with sample for approval test. 7.11 Foam Certification Data Form (Appendix A in GMW15058) – All process changes shall be recertified by the appropriate GM Engineer. 7.12 Construction Master – After GM Engineer approve Initial Material Construction, Fabric Supplier shall prepare Textile Construction Master Sample and submit it to GM (AME). Construction Master Sample shall meet the Material Construction Requirement except color property and part processibility. It shall be the same lot textile with initial construction approval which is the typical lamination and thickness for the program. GM Engineer will guide Textile Specification for initial construction approval and construction master. Specification for the Construction Master Sample is as follows. . Construction: Face Cover + Foam lamination + Scrim . Color: TBD . Size: (27.94cm wide x 40.64cm long) or A3 size (29.7cm wide x 42.0cm) . Quantity: min. 150 sheets Construction Master Sample shall be manufactured according to pattern direction by Design and it shall be shown on the label. GM (AME) will provide the label to supplier, and Construction Master Sample shall be labeled by supplier. And the position and orientation shall be followed by GM requirement. After release Construction Master, Color development will be progressed by DAQ. Textile Pattern change which is related appearance except color is not allowed after Initial Construction approval/Construction Master Release. If pattern change is needed, shall get GM confirmation in advance, restart Initial Construction approval and rerelease Construction Master. 7.13 PPAP Master – After release Construction Master by AME, Color development will be progressed by DAQ. After color approval by DAQ, PPAP Master shall be manufactured. For manufacturing and distribution of PPAP Master, Supplier shall follow the guide from DAQ. 8. Engineering Plan Do not validate Trademarks and Tradenames. 8.1 Technical Reviews Gate#1 All Samples should be progressed in production condition (Fabric with lamination) or Fabric Cover only. The fabric condition shall be same as supplier sourcing condition. 8.1.1 Completed ICE (Initial Critical/Construction Evaluation) Sheet – See Attachment. Fill all blanks refer to the example sheet. If there are any concerns with the physical properties and any risks, note it. i.e. weight, elongation, and flammability. ICE Sheet shall include tested samples for the “*” marked item on test results in the sheet. 8.1.2 Fabric Samples for ICE approval . Sample Specification: Fabric cover only or Fabric cover with lamination . Quantity: Width x min. 2m (length) The fabric samples shall be same lot with ICE Completion by supplier. . 3 of Seam Fatigue Specimen (W/W, F/F, and W/F) – If necessary, seam fatigue will be tested by GM. Supplier shall submit seam fatigue specimen pack processed in a same condition (material, thread, needle type, and manufacturing procedure) with the sample tested by supplier. 8.1.3 Fabric Samples for appearance view (A3 size x 3 sheets) for GM Engineering 8.1.4 Cost – square meter and liner yard. 8.1.5 Shall submit the lamination information (e.g. Foam supplier, location, etc) 8.1.6 Available Raw Materials – Suppliers shall have enough yarns available in house to support launch of program. 8.1.7 Cut&Sew Processability Evaluation Form (Tier-1 sign-off) 8.2 Technical Reviews Gate#2, and After All Samples after Technical Review gate#2 shall be progressed in production condition. (Fabric with lamination)

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

Page 5 of 6

Engineering Requirements & Information for Seat&Doortrim Fabric
8.2.1 Completed full Test report (Use the Construction Certification Data Form in GMW14231 Appendix B) with lab package which is required submission on GMW14231– Test Items are 3.1 General Requirements and Section 3.2 Construction Requirements in GMW14231. . Three of Seam Fatigue Specimens (W/W, F/F, and W/F) – If necessary, seam fatigue will be tested by GM. Supplier shall submit seam fatigue specimen pack processed in a same condition (material, thread, needle type, and manufacturing procedure) with the sample tested by supplier. 8.2.2 Fabric Samples for Construction approval & Processibility -The fabric samples shall be same lot with Completed full Tested sample by supplier - For Construction Approval . Sample: Textile shall be in production intention (See appendix ‘Textile Material Specification’ for details.) . Quantity: See appendix ‘Sample for approval test’ for details. NOTE: For the special samples, required by material specification, Supplier shall submit samples (width x min. 1m) as required by material specification. - For Cut&Sew Processability . Quantity: ..Fabric with lamination: width x min. 5m(length) 8.2.3 Fabric Samples for appearance view (A3 size x 3 sheets) Appendix 1. Textile material specification 2. Textile lamination 3. Sample for approval test 4. Fabric Processability Evaluation Form Note) See the appendixes in GMW14231 for the below forms. - Construction Certification Data Form - Construction Specification Sheet 8.2.4 Foam Certification Data Form (Use the Foam Certification Data Form in GMW15058 Appendix A) – Fabric suppliers are “vendor of record” for the fabric and foam composite. The foam used in any laminate for Construction approval and Processibility shall meet the requirements of GMW15058. 8.2.5 Lamination information (e.g. Foam supplier, location, etc.) 8.2.6 Cut&Sew Processability Evaluation Form (Tier-1 sign-off) 8.2.7 DFMEA analysis in paper – Test Report with tested sample for 6.5.1. 8.2.8 Construction Master

9. Key Definition .Shall – A binding provision; a must .Should – Denotes preferences when specifying alternatives or desired conformance with objectives, standards, etc. Which if not met must be documented and disclosed by the supplier and approved by the appropriate GM Authority .TBD – To be determined 10. Release and Revisions Rev Approval Date Description Initial Jun 30 2010 Original release

June 2010

Originating Department: GMDAT Appearance Material Engineering Team

Page 6 of 6


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