TITLE:

QUALITY EVALUATION STANDARD OF STEEL, ALUMINUM AND ALUMINUM ALLOY SHEETS AND COILS FOR AUTOMOBILE

1. APPLICABLE MATERIALS This Standard applies to steel sheets and steel strips for automobiles (NES M2000 series) as well as cold-rolled aluminum alloy plates for automobiles (automobile bodies) (NES M4000 series) used in Nissan Subsidiaries.

2. CLASSIFICATION OF QUALITY PROBLEMS (1) Classification of problems A summary of the steel sheet and aluminum sheet quality problems covered in this Standard is provided below. Classification 1. Packing style 2. Dimensions 3. Surface 4. Mechanical test values 5. Internal defects 6. Plating properties 7. Others Summary Packing style of coil and sheet material Coil width and sheet thickness of delivered coils and sheet material Surface quality of delivered coils and sheet material Mechanical characteristic values of delivered coil and sheet material Internal defects Plating properties Others Table 1 (2) Summary of quality problem evaluation and judgement criteria A summary of the problem classifications is provided below. Problem Rank A (Serious claim) Description Safety problem or serious accident occurred. - An accident or hazardous work occurred because of this problem. - A subsequent process (such as the vehicle body) stopped because of this problem. - A die or piece of equipment was damaged because of this problem. Safety problem, serious accident, or stoppage of subsequent process might occur; or occurrence criteria described below are met. <Surface defect control purposes> The quantity of said coils, blank materials, or products that contain defects is at least 1% (cold-rolled) or 3% (hot-rolled acid-cleaned or equivalent) per bundle or steel strip. <General purposes> - For strict-appearance materials, the quantity of said coils, blank materials, or products that contain defects is at least 3% (cold-rolled) or 5% (hot-rolled acid-cleaned or equivalent) per bundle or steel strip. - For normal-appearance materials, the quantity of said coils, blank materials, or products that contain defects is at least 5% per bundle or steel strip. - Item that does not correspond to problem rank A or B mentioned above, but is considered to include potential manufacturer-related problems. Table 2 Specific standards (criteria) are indicated in the following pages.
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B (Claim)

C (Quality information)

1. Packing style Classification

Problem

Measurement Method

Rank A

Rank B Rank C

Reference

1 Abnormal outer diameter of coil 2 Abnormal inner diameter of coil 3 Collapsed coil

Measurement with steel tape measure, etc. Measurement with steel tape measure, etc. Visual and measurement with steel tape measure, etc. Visual

Based on Table 2.

Based on Table 2.

Based on Table 2.

4 Winding defect - Bamboo shoot - Partial projection

Based on Table 2.

5 Dents

Visual

Based on Table 2.

Size delivered is not the one agreed upon with the plant. Size delivered is not the one agreed upon with the plant. Coil cannot be set in line because of coil collapse. Person in charge of blank line and the supervisor confirm that unpacking or operation is impossible due to poor winding. Based on Table 2.

Each plant blank line machine performance table Each plant blank line machine performance table Although collapse occurs, production is possible. Although winding defects occur, production is possible.

Used for general purpose and there is no problem as product. At time of delivery, band specifications (number and width) differ from normal, and there is risk of breakage. Markings are difficult to see.

6 Band defect - Circumferential longitudinal band

Visual

Based on Table 2. Production is not possible because band is not used or is broken at the time of delivery. Based on Table 2.

At time of delivery, band is not securely fixed or is starting to break, and it is handled by Nissan.

7 Identification tag defect 8 Others

Visual

Based on Table 2.

There are no marking items specified by NES. Individual handling (according to agreement between the parties concerned)

NES M 2020, etc.

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2. Dimensions Classification

Problem

Measurement Method

Rank A

Rank B

Rank C

Reference

1 Sheet thickness

Measurement with micrometer, etc. Measurement with steel tape measure, etc.

Based on Table 2.

2 Coil width - Includes length of sheet material

Based on Table 2.

3 Flatness - Wave - Edge wave - Center buckle 4 Camber

Visual and measurement as required

Based on Table 2.

Measurement based on NES

Based on Table 2.

5 Others 1 Flaws - Roll marks - Drawing marks - Seizure marks - Chatter marks - Scale (steel only) - Scratches - Scab - Others Based on visual/tactile standards and limit samples established ahead of time through separate agreement specifications. For all other cases, the following shall be regarded as defects: <Strict-appearance material> - Flaws that catch on fingernails - Flaws/patterns that can be confirmed with normal oilstone after pressing <Normal-appearance material> - Cracks and other flaws that become forming defects

Based on Table 2. Based on Table 2.

Indicated sheet thickStandard is met, but NES M 2020, etc. ness does not meet problem has occurred. NES standard. Does not meet NES Standard is met, but NES M 2020, etc., agreement document standard or agreement manufacturers volunin writing between the tary control target is not parties concerned. met, and problem has (Based on Table 2.) occurred. Does not meet NES Can visually confirm, NES M 2020, etc., agreement document standard or agreement but level permits proin writing between the duction. parties concerned. (Based on Table 2.) Does not meet NES Can visually confirm, NES M 2020, etc. standard. (Based on but level permits proTable 2.) duction. Individual handling (according to agreement between the parties concerned) Based on Table 2. There are many flaws that are not the target of the surface defect control leading to a risk of problems in forming process. NES M 2020, etc.

3. Surface

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Classification

Problem

Measurement Method

Rank A

Rank B

Rank C

Reference

2 Grime (after unpacking) - Oil smear - Oil stains - Foreign material - Contaminants - Others 3 Rust - Rust spots - Rusty edges - White rust (aluminum only) 4 Discoloration

Visual, tactile

Based on Table 2.

Based on Table 2.

Based on Table 2. - There are stains that are no problem as a product.

NES M 2020, etc.

Visual, tactile (focusing on coils that are cut within one week after coil delivery)

Based on Table 2.

Based on Table 2.

Based on Table 2. - There is rust that is no problem as a product.

NES M 2020, etc.

Visual <Strict-appearance material> Visual confirmation must be possible. <Other> For said part, discoloration must not cause forming defect.

Based on Table 2.

Based on Table 2.

Based on Table 2.

5 Surface roughness

Based on Table 2.

Does not meet NES standard with respect to high image clarity specification. (Based on Table 2.)

6 Oil application

Based on Table 2.

7 Others

Based on Table 2.

Type of rust-preventive oil or quantity of oil was changed without prior written notification and consent from Nissan, causing vehicle production problems. Individual handling (according to agreement between the parties concerned)

- Normal finish with strict purpose: Ra > 1.5 - Normal finish with general purpose: Does not meet NES reference value. Production problems have not occurred, but quantity of oil was changed; thus, future problems are expected.

NES M 2020, etc.

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4. Mechanical Classification test values

Problem

Measurement Method

Rank A

Rank B

Rank C

Reference

1 Abnormal mechanical test value - Cracks - Wrinkles - Dents Other 1 Stretcher strain 2 Structural defects 3 Internal segregation 4 Others - Rough surface - Cracks - Streaks - Bands - Unevenness Other 1 Plating defects - Abnormal amount of plating deposit - Abnormal plating composition - Nonuniformity of GI material plating 2 Peeling of plating or organic coating - Power rings - Flaking - Dross 3 Others Different from the designated organic film, etc.

JIS Z 2241/other

Based on Table 2.

Does not meet NES standard.

Based on Table 2. - Standard is met, but cracks or other problems have occurred.

NES M 2020, etc.

5. Internal defects

After press forming, determination by visual/tactile means

Based on Table 2.

Based on Table 2.

Based on Table 2.

NES M 2020, etc. (particularly aging characteristics)

6. Plating properties (steel only)

NES M 2036, etc.

Based on Table 2.

Does not meet NES standard. (Based on Table 2.)

Based on Table 2.

NES M 2036, etc.

Based on Table 2.

Based on Table 2.

Handled by Nissan (according to agreement between the parties concerned)

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Classification

Problem

Measurement Method

Rank A

Rank B

Rank C

Reference

1 Erroneous coil delivery

Based on Table 2.

Does not meet NES standard. Based on Table 2. Based on Table 2.

Others

2 Edge burring 3 Others

Based on Table 2. Based on Table 2.

Individual handling (according to agreement between the parties concerned)

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3. APPLICATION PRECAUTIONS This section describes precautionary points to remember when applying this Standard. (1) Troubleshooting Troubleshooting basically consists of the actions described below. As a practical matter, actions are determined through agreement between the parties concerned, based on the conditions of occurrence. Problem Handling Count Remarks Level Rank A Discuss between the parties concerned Implement Set target for as a matter involving a warranty (supplenumber of inmentation or compensation for loss) cidents. and/or serious claim. Rank B Request improvement as a matter involv- Implement Set target for ing a warranty (supplementation or comnumber of inpensation for loss) and/or claim. cidents. Rank C Submit information as quality information. Implement Submit results. (2) Counting the number of problem incidents In principle, incidents shall be counted as 1 incident/coil (sheet = 1 incident/bundle). (3) Problem ranks, in principle, shall be determined in the presence of the manufacturer. Also, the actual determination shall be made by the plant's Material Quality Service Section (Quality Assurance Section or Stamping Section). (4) The material quality service section shall set targets, tabulate the number of problem incidents, and issue improvement requests to manufacturers. Also, yearly summaries of the status of problems at each plant shall be prepared once a year by the Production Engineering Department. 4. APPLICATION DATE: The revision of this matter shall be applied starting on December 2, 2005. 3 5. NORMATIVE REFERENCES (1) NES M2020 (2) NES M2021 (3) NES M2027 (4) NES M2028 ; Cold Rolled Carbon Steel Sheets and Strips ; Hot Rolled Steel Plates, Sheets and Strip for Automobiles ; Zinc Coating (Hot-Dipped) on Steel Plates and Steel Strips for Automobiles 3 ; Electrogalvanized, and Zn-Ni-Electroplated Steel Sheets and Steel Strips for Automobiles (5) NES M2029 ; Hot Dipped Aluminum Coated Steel Sheets and Strips for Automobiles (6) NES M2030 ; Terne Coated and Nickel/Terne Coated Steel Sheets and Strips for Automobiles (7) NES M2032 ; High Tensile Strength Cold Rolled Carbon Steel Sheets and Strips for Automobiles (8) NES M2036 ; Durasteel Corrosion Control Coated Steel Sheets and Strips - Automobile (9) NES M2037 ; Aluminum Coated Hot-Dipped Stainless Steel Sheets for Automobiles (10) NES M4064 ; Cold Rolled Aluminum Alloy Sheets for Automobiles (for Bodies) (11) JIS Z2241 ; Method of tensile test for metallic materials

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