ADS experience vs the selection, procurement and use of automotive parts in space programs

Agenda

1. Why to use automotive parts in space?
   • • Space Market Evolution
     • Meeting the requirements
2. AEC-Q Principles
   • • Production Part Approval Process (PPAP)
     • Comparing Hi-Rel and Automotive Standards
3. Selection of Automotive Components for Space
4. Procurement of Automotive Components for Space
5. Use of Automotive Components for Space
6. Main Takeaways

Why to use automotive parts in space? – Space Market Evolution

• the use of automotive parts in space programs seems to be beneficial due to the change of needs in the space market

-> Changing needs call for new approaches / methodologies / concepts

Why to use automotive parts in space? – Meeting the requirements

• to what degree do different kind of parts meet the requirements for space programs

• automotive components are the best compromise between price & reliability (excluding radiation) for space

-> AEC-Q components provide a good compromise between price & reliability for space programs (excluding radiation)

AEC-Q Principles

• AEC-Q documents specify how to qualify components and to requalify them in case of material or process changes.

• There is no AEC Qualifying Body, auditing the manufacturers or certifying it has met the qualification requirements:
  • Manufacturers self-certify their compliance to AEC-Q requirements
  • Each user is responsible to review the qualification data to verify the compliance to AEC-Q requirements
• Quality is based on:
  • Heavy qualification procedure (several hundreds of parts)
  • Determination of Early Life Failure Rate (ELFR) – for microcircuits
  • Strict control of material and process changes
  • SPC (Statistical Process Control) based on volume

• Different grades of components are defined according to their temperature range with associated qualification tests.
  • Grade 0 : -40C to +150C (microcircuits) or -50C to +150C (passive)
  • Grade 1 : -40C to +125C (microcircuits & passive)
  • Grade 2 : -40C to +105C (microcircuits & passive)
  • Grade 3 : -40C to +85C (microcircuits & passive)
  • Grade 4 : 0C to +70C (passive – non-automotive)
• As a result:
  • No screening process is imposed.
  • No periodic lot qualification is required.

Production Part Approval Process (PPAP)

• PPAP defines the approval process for new or revised parts, or parts produced from new or significantly revised production methods. 

• There are 5 levels of PPAP submission. Generally Automotive uses the level 3 : Part Submission Warrant (PSW) with product sample and complete supporting data.
• The PPAP process consists of 18 elements that may be required for approval of production level parts. Not all of the elements are required for every submission. 

1. Design Documentation
2. Engineering Change Documentation
3. Customer Engineering Approval
4. Design Failure Mode and Effect Analysis (DFMEA)
5. Process Flow Diagram  
6. Process Failure Mode and Effect Analysis (PFMEA)
7. Control Plan  
8. Measurement System Analysis Studies  
9. Dimensional Results  
10. Records of Material / Performance Tests
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer Specific Requirements
18. Part Submission Warrant (PSW)

• The resulting PPAP submission provides the evidence that the supplier has met or exceeded the customer’s requirements and the process is capable of consistently reproducing quality parts.
• Contrary, in space, CoC (Certificate of Compliance) certifies that a series of tests has been done. It does not warrant a failure rate of components.