1 Purpose
This document establishes basic Prime Power Inc. Quality Control requirements for the Prime Power Suppliers (Seller) necessary to ensure that the supplier/services purchased from the Seller meet the required quality levels.
2 Scope
This instruction applies to Prime Power Inc. procurement activities and Prime Power Suppliers.
3 Supplier Responsibility & Applicable Requirements
It is the Seller's responsibility to comply with the requirements stated herein. Sellers are required to meet both the General requirements, Section 6, and the pertinent specific purchased product requirements section (one of sections 7 thru 12). The Section (paragraph) pertaining to these requirements are as follows:
Section 6 General Requirements
The general requirements described in this section apply to Sellers for all Purchase Orders.
6.1 Conflicting or Unclear Requirements
If the Buyer and Seller have different interpretations of the requirements, the Buyer shall resolve the conflict. If the Buyer and Seller cannot agree on the requirements, the Buyer shall provide written instructions to the Seller.
6.2 Supplier Responsibility
The Seller shall be responsible for ensuring that the product or service meets the requirements of this document.
6.3 Buyer Responsibility
The Buyer shall be responsible for providing the Seller with the necessary information to ensure that the product or service meets the requirements of this document.
6.4 Buyer's Right to Reject
The Buyer shall have the right to reject any product or service that does not meet the requirements of this document.
6.5 Buyer's Right to Return
The Buyer shall have the right to return any product or service that does not meet the requirements of this document.
6.6 Buyer's Right to Cancel
The Buyer shall have the right to cancel any purchase order that does not meet the requirements of this document.
6.7 Buyer's Right to Modify
The Buyer shall have the right to modify any purchase order that does not meet the requirements of this document.
6.8 Buyer's Right to Suspend
The Buyer shall have the right to suspend any purchase order that does not meet the requirements of this document.
6.9 Buyer's Right to Terminate
The Buyer shall have the right to terminate any purchase order that does not meet the requirements of this document.
6.10 Failure Analysis and Corrective Action Requirement
The Seller agrees to conduct failure analysis, investigation of root cause and corrective action for parts, materials or assemblies delivered that have failed during P2 testing or failed at P2's customer or field use. Seller shall provide timely replies to P2 Non-conforming Material Report (NCMR), Corrective Action Request (CAR), or Supplier or Outside Lab Failure Analysis Request (SOLFAR). Non-response or late responses will adversely affect the suppliers rating and may limit approval status for future business with Prime Power Inc.
6.11 Right of Access – Surveillance
The Buyer, customer, and regulatory agencies shall have the right of entry to Seller premises and access to applicable processes and areas of all facilities at any level of the supply chain to perform assessments necessary to ensure conformance to the requirements stated herein. The Buyer may conduct a survey and/or perform surveillance of the Seller's quality control system to evaluate the degree of ability to comply with these and other applicable requirements
6.12 Seller Flow – Down Requirements
The Seller shall flow down to Seller's sub-tier suppliers the applicable requirements contained herein. These should include the same requirements required of the Seller by this document.
6.13 Foreign Object Debris (FOD) Prevention
All parts and materials intended for Buyer shall be delivered free of FOD. All supplied products or services must be of sufficient materials and workmanship to prevent formation of FOD at any future time.
6.14 Preservation and Packaging
All parts and material intended for Buyer shall be protected against the usual hazards of ESD, corrosion, contamination, deterioration, or other spoilage at the Seller's facility and in transit. All material intended for Buyer shall be packed with suitable protection so as to prevent damage through handling, during storage at the Seller, in transit, and during storage at Buyer's facility before use. The Seller's handling, preservation, packaging and delivery processes shall contain provisions to prevent FOD.
6.15 Shipping Method/Carrier
Seller shall use shipping method or carrier as stated in Purchase order. Seller departure from shipping method/carrier as stated in Purchase Order releases P2 (Buyer) from payment of shipping costs.
6.16 Control of Records
The Supplier shall retain objective written evidence of hardware conformance to Purchase Order requirements for each shipment. All such records are subject to review and/or audit by P2. The following shall be retained for a period of 10 years if it is generated during the build of the part(s): 1. Inspection and test records used to determine item 2. Reports/certifications of chemical and/or physical analysis/test records that assure conformance to applicable 3. First Article Inspections/Tests (FAITs) 4. Special process Suppliers shall not destroy any of the records for P2 product defined above without giving P2 30 day's prior notice
6.17 First Article Inspection/Test
When indicated on the Purchase Order, Seller shall perform First Article Inspection (FAI) and furnish a First Article Inspection Report, to include actual dimensions, characteristics, test results, and verification of drawing notes in accordance with the drawing and/or specifications required by the Purchase Order. Material certifications and any special process certifications shall be submitted as part of the FAI documentation package. A copy of the FAI Report is to be included in the shipment and all first article pieces shall be identified as such in the shipment to P2.
6.18 Obsolescence
Seller notify P2 at such time seller becomes aware of a manufacturer's plans to discontinue component(s). Notification shall include recommendations of alternate parts if available and last buy timeline(s).
6.19 Electrostatic Control Plan
Suppliers providing static sensitive items, or performing a service to static sensitive items must take necessary precautions to ensure these items are protected from electrostatic charges. Additionally, suppliers are required to have an ESD Control Program available for review. It is recommended the ESD Control Program follow the guidelines of MIL-HDBK-263 (ESD Control Handbook for Protection of Electrical and Electronic Parts) or ANSI/ESD S20.20 (Protection of Electrical and Electronic Parts, Assemblies and Equipment).
7 Electronic Components
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the electronic components used in the product. The BOM shall include the part number, description, quantity, and supplier.
7.1 Plating & Tin finishes – Tin Whisker mitigation
When tin-plating with no lead (Pb) is used, only Matte-tin finish, preferably with a nickel underplate is allowed. In the matte tin finish there shall not be bright tin and no brighteners shall be used. When P2 drawing is specified, the finish requirement specified on the P2 Drawing takes precedence.
7.2 Solderability
Solderability is the ability of a metal to be wetted (wetted: formation of a relatively uniform, smooth, unbroken and adherent film of solder to a basis metal) by molten solder. The to-be-soldered-to surfaces of product delivered to Prime Power Inc. such as components, discrete devices, sub-assemblies, transformers, inductors and PWBs, shall be able to meet appropriate solderability testing as specified in J-STD-002 Category 3.
7.3 Traceability (Date Codes/Lot Numbers)
The Seller shall provide date of manufacture date code(s) and, if applicable, lot numbers on the Seller's component body (when feasible), packing slip, reel, container or packaging.
7.4 Moisture Sensitivity Level (MSL)
For all non-hermetic SMD packages subject to bulk solder reflow processes during PCB assembly, including plastic encapsulated or moisture permeable packages, when the MSL number for the part is known by the Seller, P2 requests the MSL number be indicated on the reels, packing slip, or packaging container.
8 Sub-Assemblies (i.e. Magnetics assemblies, CCAs, etc.)
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the sub-assemblies used in the product. The BOM shall include the part number, description, quantity, and supplier.
8.1 Soldering Assemblies – Tin Whisker Mitigation
When soldering assemblies such as circuit card, magnetic, or filter assemblies to be delivered to Prime Power Inc., tin/lead solder with Pb content greater than 3% shall be used. Lead free solder shall not be used.
8.2 Solderability
Solderability is the ability of a metal to be wetted (wetted: formation of a relatively uniform, smooth, unbroken and adherent film of solder to a basis metal) by molten solder. The to-be-soldered-to surfaces of product delivered to Prime Power Inc. such as components, discrete devices, sub-assemblies, transformers, inductors and PWBs, shall be able to meet appropriate solderability testing as specified in J-STD-002 Category 3.
8.3 Soldering Acceptance Criteria
Soldered assemblies (e.g. Magnetics, Circuit Card Assemblies, connector assemblies, etc.) shall meet the acceptance criteria of IPC-A-610 Class 3.
8.4 Age Control
The Seller shall maintain a system for age control items where acceptability or usability of the item is limited by maximum age. The system shall include a method of identifying and controlling such items.
9 PWBs (PCBs)
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the PWBs used in the product. The BOM shall include the part number, description, quantity, and supplier.
9.1 PWB Design Requirement
PWBs shall be designed to meet the requirements of IPC-2221 Class 3, Level C
9.2 PCB Fabrication Requirement
For rigid printed wiring boards the qualification and performance requirements shall meet the requirements of IPC-6012 class 3. Where the requirements of IPC-6012 class 3 cannot be met, the PWB supplier shall obtain written approval from P2 to depart from these requirements
9.3 Thru-hole Copper Plating Thickness
On all thru-holes with plating, the copper plating thickness shall be greater than 0.0010 inch.
9.4 PWB Thickness and Condition
Overall thickness includes all plating and is measured from metal to metal. Remove all burrs and break sharp edges.
9.5 Cross-section / micro-section
PWB supplier shall retain coupon cross-section/micro-section examination data and results for a minimum of 5 years. For each lot delivered the PWB supplier shall provide the laboratory cross section analysis report that shows the actual dimensions or as applicable, acceptability statement to the IPC-6010 applicable requirements (IPC-6012 3.6.2.1 thru 3.6.2.17) for the Micro sectioned coupons. Additionally the PWB supplier shall also provide the cross sectioned coupon identified to the part number and lot number of the PWB fabricated. Upon Buyer request, PWB seller shall be able to provide a cross section / micro section of a PWB taken from an area of the board (not the panel) for use in evaluation and analysis for the inner layer structure. During Micro section coupon examination, nonconformance's (rejections) shall be annotated on the data and the PWBs containing the nonconformances shall not be delivered without written approval form P2. PWB supplier shall not accept verbal directions from P2 to depart from requirements of the applicable drawings and its specification call outs or references (e.g. IPC 6012)
9.6 PWB Conductor Width
The finished PWB conductor widths shall meet the P2 design data (drawing or gerber data).
9.7 PWB Inner layer thickness
The finished PWB inner layer dielectric thickness shall meet P2 design data (Gerber data and Drawing).
10 Custom Metal Fabricated Parts
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the custom metal fabricated parts used in the product. The BOM shall include the part number, description, quantity, and supplier.
10.1 Burrs and sharp edges
Fabricated parts shall be free of all burrs and sharp edges.
10.2 Helical Wire Insert Requirements
When using tanged helical wire inserts, after installation of the helical wire insert the tang must be removed. Tangs left inside can be a source of FOD and/or cause interference when installing screws.
10.3 Cleanliness
Parts shall be cleaned adequately to remove any visual evidence of residues or contaminants. All surfaces shall be free of contaminants introduced during deburring, polishing or other processing.
11 Hardware & Wire
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the hardware and wire used in the product. The BOM shall include the part number, description, quantity, and supplier.
11.1 Preference for Domestic Specialty Metals
Compliance to Defense FAR Supplement (DFARS) 252.225-7014, Alt 1, is required for this purchase order or any delivery to P2 of product containing "Specialty Metals" as defined by DFAR 252.225-7014, Alt 1. This requirement, DFARS 252.225-7014, Alt 1; must be flowed down into subcontracts and purchase orders at every tier. Seller shall not knowingly ship non-DFARS conforming material or product without written authorization from Prime Power Inc.
12 Chemicals
The Seller shall provide the Buyer with a Bill of Materials (BOM) that lists all the chemicals used in the product. The BOM shall include the part number, description, quantity, and supplier.
12.1 Shelf Life – Age Controlled Material
The supplier shall identify all materials that have definite characteristics of quality degradation with age and/or environment. The supplier shall affix this information directly on the material container and include it on the certification (C of C) document. This information shall indicate the date useful life was initiated and the date at which life will be expended. When environment is a factor in determining useful life, the identification shall include storage conditions or requirements. A minimum of 75% of the applicable shelf life shall remain upon receipt of the material by P2 or the material is subject to rejection and return to the supplier for replacement.
12.2 PentaBDE and OctaBDE
Products delivered to P2. shall not contain concentrations of Pentabromodiphenyl ether (PentaBDE) or Octabromodiphenyl ether (OctaBDE) higher than 0.1% by mass. The supplier shall disclose to P2 the existence of these materials contained in the product prior to actual delivery.
12.3 European Union Restriction on Hazardous Substances (RoHS) Listed Materials
Products delivered to P2. shall not contain materials listed in the European Union (EU) Directive 2002/95/EC (RoHS) in concentrations beyond allowable deminimus amounts including 0.1% by weight in homogeneous materials for lead, mercury, hexavalent chromium, polybrominated biphenyls (PBB) and polybrominated diphenyl ethers (PBDE) and 0.01% by weight in homogeneous materials for cadmium. Homogeneous material means a material that can not be mechanically disjointed into different materials. This requirement applies to all materials listed in the EU directive as amended.
12.4 European Union Registration, Evaluation, Authorization and Restriction of Chemicals (REACH)
Unless explicitly described in purchase order, the following requirement does not apply to solder or soldered assemblies. Products delivered to P2. shall not contain materials identified as Substances of Very High Concern (SVHC) by the European Chemicals Agency pursuant to EU Regulation (EC) No. 1907/2006 in concentrations above 0.1% by weight in homogeneous materials. Because of the evolving nature of that regulation, suppliers are advised to consult the current SVHC list at www.echa.europa.eu.
Effective Date: January 1, 2024
Last Updated: January 1, 2024