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 se-

ries) 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 Summary

1. Packing style Packing style of coil and sheet material 2. Dimensions Coil width and sheet thickness of delivered coils and sheet

material 3. Surface Surface quality of delivered coils and sheet material 4. Mechanical test values Mechanical characteristic values of delivered coil and sheet

material 5. Internal defects Internal defects 6. Plating properties Plating properties 7. Others Others

Table 1

(2) Summary of quality problem evaluation and judgement criteria

A summary of the problem classifications is provided below. Problem Rank Description

A (Serious claim)

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.

B (Claim)

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 ma-

terials, 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.

C (Quality information)

- 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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Cla

ssifi

catio

n

Problem Measurement Method Rank A Rank B

Rank C Reference

1 Abnormal outer diameter of coil

Measurement with steel tape measure, etc.

Based on Table 2.

Size delivered is not the one agreed upon with the plant.

Each plant blank line machine performance table

2 Abnormal inner diameter of coil

Measurement with steel tape measure, etc.

Based on Table 2. Size delivered is not the one agreed upon with the plant.

Each plant blank line machine performance table

3 Collapsed coil Visual and measurement with steel tape measure, etc.

Based on Table 2. Coil cannot be set in line because of coil col-lapse.

Although collapse oc-curs, production is pos-sible.

4 Winding defect - Bamboo shoot - Partial projection

Visual Based on Table 2. Person in charge of blank line and the su-pervisor confirm that unpacking or operation is impossible due to poor winding.

Although winding de-fects occur, production is possible.

5 Dents Visual Based on Table 2. Based on Table 2. Used for general pur-pose and there is no problem as product.

6 Band defect - Circumferential longitudinal band

Visual Based on Table 2. Production is not possi-ble because band is not used or is broken at the time of delivery.

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

At time of delivery, band specifications (number and width) differ from normal, and there is risk of break-age.

7 Identification tag defect

Visual Based on Table 2. There are no marking items specified by NES.

Markings are difficult to see.

NES M 2020, etc.

1. P

acki

ng s

tyle

8 Others Based on Table 2. Individual handling (according to agreement between the parties concerned)

3

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C

lass

ifica

tion

Problem Measurement Method Rank A Rank B Rank C Reference

1 Sheet thickness Measurement with micrometer, etc.

Based on Table 2. Indicated sheet thick-ness does not meet NES standard.

Standard is met, but problem has occurred.

NES M 2020, etc.

2 Coil width - Includes length of sheet material

Measurement with steel tape measure, etc.

Based on Table 2. Does not meet NES standard or agreement in writing between the parties concerned. (Based on Table 2.)

Standard is met, but manufacturer’s volun-tary control target is not met, and problem has occurred.

NES M 2020, etc., agreement document

3 Flatness - Wave - Edge wave - Center buckle

Visual and measurement as re-quired

Based on Table 2. Does not meet NES standard or agreement in writing between the parties concerned. (Based on Table 2.)

Can visually confirm, but level permits pro-duction.

NES M 2020, etc., agreement document

4 Camber Measurement based on NES Based on Table 2. Does not meet NES standard. (Based on Table 2.)

Can visually confirm, but level permits pro-duction.

NES M 2020, etc.

2. D

imen

sion

s

5 Others Based on Table 2. Individual handling (according to agreement between the parties concerned)

3. S

urfa

ce 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 con-

firmed with normal oilstone after pressing

<Normal-appearance material> - Cracks and other flaws that be-

come forming defects

Based on Table 2. Based on Table 2. There are many flaws that are not the target of the surface defect control leading to a risk of prob-lems in forming process.

NES M 2020, etc.

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Cla

ssifi

catio

n

Problem Measurement Method Rank A Rank B Rank C Reference

2 Grime (after un-packing)

- Oil smear - Oil stains - Foreign material - Contaminants - Others

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.

3 Rust - Rust spots - Rusty edges - White rust (alumi-num only)

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.

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

Based on Table 2. Based on Table 2. Based on Table 2.

5 Surface rough-ness

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

- Normal finish with strict purpose: Ra > 1.5

- Normal finish with general purpose: Does not meet NES reference value.

NES M 2020, etc.

6 Oil application 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 produc-tion problems.

Production problems have not occurred, but quantity of oil was changed; thus, future problems are expected.

7 Others Based on Table 2. Individual handling (according to agreement be-tween the parties concerned)

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C

lass

ifica

tion

Problem Measurement Method Rank A Rank B Rank C Reference

4. M

echa

nica

lte

st v

alue

s 1 Abnormal me-chanical test value

- Cracks - Wrinkles - Dents Other

JIS Z 2241/other Based on Table 2. Does not meet NES standard.

Based on Table 2. - Standard is met, but

cracks or other prob-lems have occurred.

NES M 2020, etc.

5. I

nter

nal

defe

cts

1 Stretcher strain 2 Structural defects 3 Internal segrega-

tion 4 Others - Rough surface - Cracks - Streaks - Bands - Unevenness Other

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)

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

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.

6. P

latin

g pr

oper

ties

(ste

el o

nly)

3 Others Different from the designated organic film, etc.

Based on Table 2. Based on Table 2. Handled by Nissan (according to agree-ment between the par-ties concerned)

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C

lass

ifica

tion

Problem Measurement Method Rank A Rank B Rank C Reference

1 Erroneous coil de-livery

Based on Table 2. Does not meet NES standard.

2 Edge burring Based on Table 2. Based on Table 2. Based on Table 2.

Oth

ers

3 Others Based on Table 2. Individual handling (according to agreement between the parties concerned)

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, ac-tions are determined through agreement between the parties concerned, based on the con-ditions of occurrence.

Problem Level

Handling Count Remarks

Rank A Discuss between the parties concerned as a matter involving a warranty (supple-mentation or compensation for loss) and/or serious claim.

Implement Set target for number of in-cidents.

Rank B Request improvement as a matter involv-ing a warranty (supplementation or com-pensation for loss) and/or claim.

Implement Set target for number of in-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 (Qual-ity Assurance Section or Stamping Section).

(4) The material quality service section shall set targets, tabulate the number of problem inci-dents, 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 ; Cold Rolled Carbon Steel Sheets and Strips (2) NES M2021 ; Hot Rolled Steel Plates, Sheets and Strip for Automobiles (3) NES M2027 ; Zinc Coating (Hot-Dipped) on Steel Plates and Steel Strips for Automobiles (4) NES M2028 ; Electrogalvanized, and Zn-Ni-Electroplated Steel Sheets and Steel Strips for

Automobiles

3

(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 Automo-

biles (7) NES M2032 ; High Tensile Strength Cold Rolled Carbon Steel Sheets and Strips for Auto-

mobiles (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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