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Requirement
Specification
Date: 2015-02-09
Mercedes-Benz Genuine
Remanufactured Parts
Entire vehicle
System
Module
Component
KG: 14
Project team
Torsten Brger
GSP/RMT
Phone:
+49 711 17
e-mail:
torsten.buerger@daimler.com
Date:
Document w/o Signature. Released in Daimler Truck Documentation System.
Christoph Hofmann
GSP/RMM
Phone:
+49 711 17
e-mail:
christoph.hofmann@daimler.com
Date:
Document w/o Signature. Released in Daimler Truck Documentation System.
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Requirement Specification
Draft
Mercedes-Benz
Genuine Remanufactured Part
Urea Pump Module Air Assisted
This document is protected by copyright. Any usage outside of the strict boundaries of copyright law without the approval of
Daimler AG is impermissible.
Page 1
Preface:
Proposals regarding detailed solutions on the part of a potential contractor are expressly desired. Particularly if
these serve as distinguishing features in comparison with competitors and correspond to the buyers' interests.
The integration of such solutions must be achievable within the framework of the cost target and scheduling.
The contractor is obliged to carry out his service using experienced and qualified personnel.
If additional companies are engaged as development partners/sub-suppliers, Daimler AG must be notified of
this.
Within the framework of this concept competition, the potential contractor must establish technical
specifications.
Should, contrary to expectation, different requirements be defined for a particular function or characteristic in
these requirement specifications, the more demanding requirement applies in all cases.
The technical specification must reflect the structure of the requirement specification. Deviations from the
requirements stated in this requirement specification must be explicitly identified in writing in the technical
specification. If deviations are not identified, the stipulations contained in this requirement specification take
precedence.
This requirement specification and the technical specification (supplier) form parts of the agreement as
technical appendices.
In the event of questions regarding the content of this requirement specification, please contact the author or
the authoring department.
Secrecy:
The results which have been generated may only be published or passed on to third parties with the approval of
Daimler AG. The contractor must oblige both his employees and any subcontractors to adhere to these
regulations. The contractor is also obliged to adhere to Point 5 of the purchasing conditions pertaining to
production material and spare parts for motor vehicles. Further details are regulated by a separate secrecy
agreement.
Blocking note:
All versions, data and contents of this requirement specification must be treated in strict confidentiality and
may not be put to further use or made accessible to third parties without the written approval of Daimler AG.
Reprinting and copying, including excerpts, are not permitted. This blocking note applies unreservedly.
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Requirement Specification
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Genuine Remanufactured Part
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Daimler AG is impermissible.
Page 2
Changes:
The partner is obliged to inform Daimler AG in advance in the event of all planned changes to products and
process procedures. Changes that effect the herewith defined product characteristics may only be carried out
following written approval by Daimler.
KEM
R-00036114
R-00036114
Date
06.08.14
09.02.15
Name
GSP/RMM(T)
GSP/RMT
Release
001
002
Reference Documents:
Follong documents are fundamental for this requirement specification:
03
04
Document No.
09150861b
A 000 140 15 78
09150358f
A 000 140 04 78
09150461d
A 000 140 05 78
09150848c
A 000 140 27 78
Date
22.02.12
Name
Cummins.
Emission Solution
26.04.07
Hydraulik Ring
Automobiltechnik
28.04.11
Hilite International
22.06.11
Cummins.
Emission Solution
05
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Page 3
Table of contents
1
General
1.1
1.2
6
9
9
1.2.2
1.2.3
Project Environment
10
2.1
2.2
2.3
Project Organization
Deadlines/Milestones
Planned unit numbers
2.3.1
Sample Parts
10
11
12
12
2.3.2
Series Parts
12
Duration contract
12
2.4
General Requirements
13
3.1
3.2
3.3
3.4
3.5
3.6
General Information
Costs and Cost-Effectiveness
Tooling Costs
Core Process
Core Acceptance and Infill Strategy
Logistics
3.6.1
Core Return Process
13
14
14
14
15
16
16
3.6.2
16
3.6.3
16
3.7
3.8
3.9
3.10
3.11
3.12
Warranty
Currency
Documentation and Product Data Management
Quality Management
3.10.1 Quality Management 1 Product Quality
17
17
18
19
19
3.10.2
19
3.10.3
19
Environmental Protection
Labelling
3.12.1 General Marking Quality
19
20
21
3.12.2
22
3.12.3
23
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Technical Requirements
4.1
4.1.1
Remanufacturing Specification
General Requirements
25
25
4.1.2
Component specification
26
4.1.3
29
4.1.4
29
4.2
4.2.1
Miscellaneous
General data
30
30
4.2.2
30
4.2.3
Operating condition
30
4.2.4
30
4.3
4.4
25
4.3.1
31
31
4.3.2
Functional Test
31
4.3.3
Endurance Test
32
4.3.4
32
4.3.5
32
4.3.6
Salt spray test (with urea pump module air assisted in operation)
32
Residual requirements
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Requirement Specification
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1 General
1.1
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Page 6
Urea Pump
Decompression Valve
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1.2.1
Assembling of components
Final testing
Labelling
Packaging
Shipping
Benefit to the customer
Provide the customer a cost-efficient remanufactured Urea Pump Module Air Assisted with a reasonable
and adequate quality level.
1.2.2
The remanufactured Urea-Pump Module-Air Assisted will be used in all markets in which it is allowed to
mount reman parts.
1.2.3
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2 Project Environment
2.1
Project Organization
The departments responsible for the AdBlue Pump Module remanufacturing project are comprised as
follows:
As contact partners the following persons are defined:
Designation
Name
Telephone
Christian Medau
Series Development
Sebastian Hummel
Purchasing
Asuncion Casanovas-Tunze
Marie-Christin Ueberfeldt
Luetfi Oektem
Thorsten Reinert
Remanufacturing Engineering
Christian Medau
Core Logistics
Jonatan Schiller
Service Engineering
Martin Stoebener
Andre Guenther
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2.2
Deadlines/Milestones
Designation
Date
Goal achievement
Project Plan
15.08.2014
Requirement specification
15.08.2014
15.08.2014
16.02.2015
Quotation Review
27.02.2015
02.03.2015
Sample evaluation 1
10 weeks
before
audit
8 weeks
before
audit
Sample evaluation 2
6 weeks
before
audit
Samples per each part number meet all technical requirements of specification and validation documentation is available.
Supplier audit
end of
august
2015
within audit
Process release.
SOP
SOP -
09/2015
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2.3
2.3.1
Sample Parts
2.3.2
Each Part number minimum one validation procedure (includes all tests mentioned in chapter 4.3.1) for validation of:
- Functionality
-
Appearance
paintwork durability
labelling durability
Series Parts
5.700
5.400
2017
5.200
The exact quantity and delivery schedule will be determined by the Global Logistics Center (GLC) in
Germersheim.
2.4
Duration contract
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3
3.1
General Requirements
General Information
The goal of the remanufacturing technology is to remanufacture and reuse defective, used or nonfunctioning Urea-Pump Module-Air Assisted with definded, specified processes.
Not reusable parts must be labelled and declared to Daimler AG and must be sent back to Daimler AG Core
Consolidation Center in Offenbach.
To avoid failures or customer complaints the remanufactured Urea-Pump Module-Air Assisted must meet all
specified technical requirements. Deviations are not acceptable unless statistical data or tests ensured the
functionality and reliability of the part or additional agreements are made.
Urea-Pump Module-Air Assisted which are not listed in this specification have to be handled separately
according to separate agreed specifications.
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3.2
Beside qualitative aspects, also the remanufacturing process and incidential costs will be checked by
responsible contact person at Daimler AG Pre-Cost Planning.
3.3
Tooling Costs
Supplier provides all necessary tooling and is therefore owner of all tooling equipment provided by
themselves.
3.4
Core Process
For remanufacturing of air-assisted urea pump module, cores are provided by Daimler AG.
The acquisition of cores depends on delivery order from Global Logistics Center Germersheim and is steered
by Supplier.
The accounting of cores is executed by Daimler AG with a price per unit negotiated with Daimler AG purchasing Department. Daimler AG delivers the cores to Supplier Germany exclusively for remanufacturing purposes for Daimler AG.
The number of cores used for remanufacturing is documented and will be communicated to Core Consolidation Center in Offenbach on a quarterly basis.
Scrapping of cores which cannot be used for remanufacturing will be documented by Supplier. Scrapping
documentation can be claimed by Daimler AG at any time. Daimler AG is allowed to conduct random inspections.
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3.5
Daimler is responsible for reviewing and approving acceptable core before sending to Supplier Germany
accoring to the core acceptance criteria.
Mercedes-Benz Genuine Remanufactured Parts Standard Core Return Criteria Requirements are binding.
1. Mechanical
2. Assembled/ Disassembled
3. Outer Corrosion
see Appendix
Supplier is responsible for notifying Daimler if any core received does not meet acceptable core criteria for
remanufacturing.
Daimler receives100 remanufactured finished goods in return for 100 acceptable* cores sent to Supplier
Germany.
*Acceptable is defined by Mercedes-Benz Genuine Remanufactured Parts Standard
Core Return Criteria Requirements.
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3.6
Logistics
Unless otherwise expressly agreed, general agreements regarding logistics are included in Mercedes-Benz
Special Terms.
3.6.1 Core Return Process
In general Core Return Process is defined as follows:
1. Delivery (Back-in Box) via CORS (Dealer LC/ELC CCC)
2. Appraisal in Core Consolidation Center
3. Shipping via Supplier Order (Based on Delivery Order from Global Logistics Center Germersheim) to
Supplier Germany done by Daimler AG
Shipping from Supplier Germany to remanufacturing plant done by Supplier (Sufficiently protected
during storage and transportation. (shock-proof, avoid scratches, avoid direct moisture, avoid
damage by crushing or impacts)
3.6.2
3.6.3
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3.7
Warranty
General agreements regarding warranty are equal to new part number A0001404478 which is 24 months.
3.8
Currency
The remanufactured UA1 sale price between supplier and Daimler will be in euros, which is analogous to the
New UA1 sales price agreement.
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3.9
Supplier has to document all relevant remanufacturing processes and store appropriate data. Supplier has to
commit to Daimler AG to verify correct Remanufacturing processes based on requirement specification, product specification, drawings with Verification Tests and calculations. Daimler AG is authorized to have complete
inspection of process data and documentation.
All Cores (Mercedes-Benz Genuine Part and Mercedes-Benz Genuine Remanufactured Part and MercedesBenz Genuine Parts for Recycling Process) have to be documented and labelled according to this requirement
specification and Mercedes-Benz-Norm (MBN).
Specified data have to be transferred via defined processes and data interfaces to Daimler AG if required.
If Data transfer is required, Data Transfer requirements will be specified by Daimler AG.
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3.12 Labelling
The marking is to be made depending on the existing or planned marking system, service life and quality requirements directly on the component by an inkjet printer, laser or a dot marking machine. In exceptional
cases, i.e., where there is good reason to use alternative marking processes, these are to be approved by
Daimler. Every part that is given a marking is to be presented to Daimler for inspection of code quality and
surface.
Humanly legible marking must be chemically and physically resistant; resistant to mechanical strains arising
during the remanufacturing process, transportation and the processing of common materials; resistant to
temperatures between 40C +85C; and legible by machine for the duration of a vehicle service life of 15
years.
For the traceability of all parts, the supplier must ensure that a link is established between human readable
identification number and its database. The type of link is left to the manufacturer.
When issues with noticeable parts arise, Daimler shall provide the supplier with the data of the component in
question and must receive from the supplier a reply stating which other components named by the human
readable identification number are affected or which individual parts / individual part numbers are installed.
These documents are to be archived and made available on demand at the supplier after the expiration of the
15-year series production.
The respective markings of individual components must not in any way influence the functionality, safety or
established values from the specifications for the components and the overall system for the duration of the
product service life of individual components and the overall system.
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Quality of markings on
metallic surfaces
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Mercedes-Benz Logo
2. Part Number
A XXX 140 XX 78
3. Drawing status
ZGS 00X
4. Identification number
5. Drawing number
XXXXXXXXXXXX
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2. Part Number
A XXX 140 XX 78 80
(All reman parts must be labelled with latest design status currently A 000 140 15 78 80)
(Part number will be specified during project)
3. Drawing status
ZGS 00X
4. Serial number
to be defined
5. Supplier Logo
Behind part number, a _ _ 80 number is added to symbolize Mercedes-Benz Genuine Remanufactured Parts.
The ES1 (means 80) index is appended with a distance of two spaces to the part number.
Following Labelling content on Mercedes-Benz Urea Genuine Remanufactured Part Urea Pump Module Air
Assisted are minimum binding:
1. Mercedes-Benz Logo
A XXX 140 XX 78 80
2. Serial number
to be defined
Labelling Location:
-
Supplier labelling must not interfere with labelling requirements specified in chapter 3.12.3.
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4
4.1
Technical Requirements
Remanufacturing Specification
The objective of remanufacturing technology is to recover, remanufacture and reuse defective parts also
known as core parts. The goal of the remanufacturing technology is to have a high ratio of remanufactured
parts versus the supplied core parts.
Not reusable Urea pump Modules Air Assisted must be declared to Daimler AG and must be send back.
Investigation on route cause can be made upon specific DAI request.
To avoid failures or customer complaints the remanufactured Urea-Pump Module-Air Assisted must meet all
technical requirements. Deviations are not acceptable unless statistical data or tests ensured the
functionality and reliability of the part.
4.1.1 General Requirements
Ambient Temperature: Tamb = -40C + 85C
Storage Temperature: Tsto = -40C + 85C (max. 90C only one time for 120min.)
Medium Temperature: Tmed = -40C + 65C (in operation: -10C + 65C)
Nominal voltage.
12 / 24 VDC depending on model
Flow rate:
Filter fineness:
20 30 m
700 cm2
Operation Temperature: -40C to +85C
Filter surface:
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4.1.2
Component specification
Appearance
Housing
Accumulator body
Fittings
Connections
Labelling
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Paintwork if necessary.
discoloration allowed.
discoloration allowed.
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supplier facility.
-
Functionality
Relief/ Air Valve:
Pressure Bladder:
Replacement Parts:
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Components reuse:
Salvage:
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4.1.3
A general component repair is not acceptable unless statistical and reliability data prove that repaired
components meet the OEM technical requirements. Component repair on critical parts i.e. housing, motor is
not accepted.
4.1.4
Winding must be checked for short to ground or for short between the windings. Winding resistance must be
measured and verified.
Brush holder functionality must be given. Any kind of damage of the brush holder are not acceptable and
must be replaced. Brushes must be replaced by shortening (length < 80%). Springs must be replaced.
Commutator roundness must be within cirularity tolerance. Commutator must be even by lathe to remove
brush marks to achieve necessary grinding surface for high and stable functionality and durability.
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4.2
Miscellaneous
4.2.1
General data
According to Drawings.
Operating condition
Temperature limits of individual components shall not be exceeded while operating at specified temperature
range.
4.2.4
International Material Data Sheet must be considered to fulfil international laws und regulations regarding
materials used in automobile industry. IMDS can be considered in /be part of process and product audit
performed by Daimler AG.
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4.3
A testing and validation of all remanufactured urea pump module Air Assisted part numbers is required
prior to the technical release of each part. For replacement parts from non OE supplier and for paintwork
and screw connection/ Gluing concepts a temperatur shock test under continous monitoring of the device
under test and a sinusoidal vibrations test are required. Supplier must provide samples to Daimler AG.
Validation tests (salt spray, temperature shock test, sinusoidal vibration) will be performed by Daimler AG.
Test results must be documented in a final test report and be provided.
4.3.1
Product Validation
For product validation, test samples (one piece per each part number) have to be tested according to the
following procedure and have to be fully functional afterwards.
A 000 140 04 78
A 000 140 05 78
A 000 140 15 78
A 000 140 27 78
Functional test
Salt Spray
Temperatur Shock test
Vibration test
Endurance test
Appearance check
4.3.2
Functional Test
Version 2015/02/09
Daimler AG
Mercedes-Benz
ALL RIGHTS RESERVED
- Property of Daimler AG -
Requirement Specification
Draft
Mercedes-Benz
Genuine Remanufactured Part
Urea Pump Module Air Assisted
This document is protected by copyright. Any usage outside of the strict boundaries of copyright law without the approval of
Daimler AG is impermissible.
Page 31
Duty Cycle:
95%
1 Hz
Operating Pressure
4.5 bar
Test Duration:
250 hours
Functional Test:
Ambient Temperature:
Supply Voltage:
Operation Medium:
4.3.4
To be specified.
4.3.6 Salt spray test (with urea pump module air assisted in operation)
Based on DIN 50021 and ASTM B117
Component in mounting position, all electrical lines connected.
Test time:
Salt concentration:
96 h
5% NaCl
Spray time:
6 min/h
Rest:
Temperatur:
35 5 C
Rating: After test with the specified values the urea pump module air assisted must be fully functional by
definition.
Version 2015/02/09
Daimler AG
Mercedes-Benz
ALL RIGHTS RESERVED
- Property of Daimler AG -
Requirement Specification
Draft
Mercedes-Benz
Genuine Remanufactured Part
Urea Pump Module Air Assisted
This document is protected by copyright. Any usage outside of the strict boundaries of copyright law without the approval of
Daimler AG is impermissible.
Page 32
4.4
Residual requirements
Every component has to fulfill a certain degree of cleanliness in order to assure proper functionality of the
Urea Pump Module Air Assisted. Cleaning results have to be verified. A certain amount of residuals can
cause malfunctions. Malfunctions are not allowed. The functional and visual cleanliness of components has
to be specified during the project to ensure constantly high quality.
Residual requirements of Mercedes-Benz Genuine Remanufactured Part - Urea Pump Module Air Assisted
is specified in DBL 6510 Technical Cleanliness of Mercedes-Benz.
Version 2015/02/09
Daimler AG
Mercedes-Benz
ALL RIGHTS RESERVED
- Property of Daimler AG -
Requirement Specification
Draft
Mercedes-Benz
Genuine Remanufactured Part
Urea Pump Module Air Assisted
This document is protected by copyright. Any usage outside of the strict boundaries of copyright law without the approval of
Daimler AG is impermissible.
Page 33