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What is an initial sample test report (EMPB)?
Zur Zeit- und Kostenreduktion ist es wichtig, etwaige Produktionsfehler frühzeitig zu erkennen und zu vermeiden. Daher werden Produkte erst dann in hoher Stückzahl produziert, wenn Serienfertigung unter realistischen Bedingungen erprobt und bemustert wurde. Entsprechen diese Erstmuster den Qualitätsanforderungen, erfolgt die Produktionsfreigabe. Durch diesen Prozess wird zuverlässig, dass Unternehmen Waren oder Produkte erst dann produzieren, wenn sie den erforderlichen Qualitätsstandards entsprechen. Bekannt ist diese Qualitätsprüfung als Erstmusterprüfung, deren Ergebnisse im Erstmusterprüfbericht festgehalten werden.
But what is the initial sample test report (EMPB)? The initial sample test report (EMPB) is an important part of the initial sample test. It documents the results of the sampling process for an "initial sample".
The initial sample inspection report not only plays an important role within the company. It is also of immense importance in the B2B sector. For example, a supplier can prove that the delivered products meet the customer's quality requirements.
Why is an initial sample test report necessary?
Ein Erstmusterprüfbericht wird entweder nach den Vorgaben eines Kunden oder nach den eigenen Qualitätsvorstellungen eines Unternehmens durchgeführt. Damit soll kontrolliert werden, ob ein Produkt serienfähig ist und in gleichbleibender, konstanter Qualität produziert werden kann. Um Antworten auf diese Fragen zu finden, wird eine festgesetzte Stückzahl der jeweiligen Produkte untersucht und die Ergebnisse im Erstmusterprüfbericht dokumentiert. Das Ziel ist die Fehlerreduzierung und -vermeidung bereits vor der Serienfertigung. Außerdem können in der B2B-Branche Kunden und Lieferanten mit einem Erstmusterprüfbericht grundlegende Vereinbarungen treffen. Die Prüfberichte unterscheiden sich in ihrer Komplexität und in ihrem Umfang oft deutlich voneinander. Des Weiteren ist ein Erstmusterprüfbericht auch bindend. Das heißt: Bei einer erneuten Produktion des geprüften Produkts, muss es dem Erstmuster, soweit keine Fehler erkannt wurden, entsprechen. Das bedeutet aber auch, dass alle neu produzierten Waren, unter den gleichen Bedingungen hergestellt werden müssen, wie auch das Erstmuster. Nur so kann eine gleichbleibende Qualität zuverlässig werden. Denn bereits kleinste Veränderungen können dazu führen, dass eine Produktion anders verläuft, als geplant. Die Gründe dafür können vielfaltig sein:
- Incorrect settings on the production machines.
- Incorrectly designed production parameters.
- Defects in the means of production.
- Errors in the measuring equipment.
- Error in the specification of the source material.
- Environmental influences not taken into account.
- Influences not taken into account due to on-site conditions.
Example scenario to explain the necessity of initial sampling:
Once a product is ready for series production, a test series is carried out for initial sampling before actual production. This reveals that the initial samples tested deviate from the dimensional specifications and the desired quality. When investigating the causes, it is recognized that, for example, the clamping force of the tools was not high enough or the air was too dry and the processed material therefore experienced a negative change. Only with the initial sample inspection report is it possible for the manufacturing company to carry out a precise analysis of the actual situation and eliminate the causes or errors.
What is the reason for an initial sample inspection?
Die Gründe für eine Erstmusterprüfung können vielfaltig sein. Unter anderem:
- Cooperation with a new supplier/sub-supplier of materials
- A new production part
- Changed product specifications
- New or modified tools
- New or modified manufacturing processes
- New production facilities
- An interruption in production
What are the economic reasons for an initial sample inspection report?
The initial sample test report is used to determine whether the planned series production is actually economically viable. The initial sample test report therefore provides a comparison between the target data of a produced item and the average properties from pre-series production.
Only when the planned manufacturing process appears viable and correct in reality is continuous production with consistent quality and increasing profitability likely.
Is the initial sample test report subject to certain standards and specifications?
Incidentally, the initial sample test report is not a "German invention". In general, it is common practice in industry. It is laid down in the VDA, Volume 2 - Quality Assurance of Deliveries. Volume 2 of the VDA generally describes the procedures for production process and product approval. This is a core element for customer-specific requirements.
Other applicable standards in connection with the sampling of an initial sample and the preparation of a test report are
- All specifications of the QS 9001 and VDA series as well as ISO TS 16949 (as amended).
- Relevant DIN ISO standards.
- Purchasing conditions for production material, spare parts and direct means of production of the products.
Where does initial sampling come into play?
Initial sampling is standard, especially in the automotive industry. Standardized guidelines, such as IATF 16949 and PPF/PPAP, ensure a standardized product sampling process in the automotive industry and close cooperation between the customer and the supplier. However, initial sampling is also the order of the day in all other manufacturing companies. Especially when new products are to be launched on the market.
Scope of an initial sample inspection report
In order to be able to make valid statements about a new product, it is not sufficient to sample the first product produced in series production. Only after a statistically reliable quantity is a qualified statement about the usability of the production and the production conditions possible. The quantity of products tested for the initial sample test report is based on the empirical values that have already been gained in connection with the production equipment. These include the wear limits of the processing machines. For example, tolerance deviations in the cavities of injection, casting, press and die-casting molds are quite normal after a corresponding number of cycles. In the same way, carbide milling cutters and indexable inserts also wear at different rates when machining materials of different hardness or softness.
Scope of testing during initial sampling
The scope of the initial sample inspection depends on the specifications and tolerances. However, the visual, metric and technical properties of a manufactured product are usually checked during the initial sample inspection.
- Optical properties include burrs, porous material, roughness, dents, scratches and clouding.
- The metric properties are some of the most important aspects of the initial sample inspection. All dimensions and weights are checked here. The products are checked manually, by tactile or optical measurement. Measurements with a computer tomograph are also possible here.
- When testing the technical properties, the load-bearing capacity of a product is examined. Tensile, breaking and bending tests can be carried out for this purpose. As soon as non-destructive tests are required, X-ray and ultrasound tests are used. Another part of technical testing is the examination of the material composition of the starting material. This is achieved using a spectrometer.
In general, the scope of testing is always tailored to the respective product. The respective manufacturers and testing service providers agree this in advance.
What happens if the initial sample test report is negative?
Ideally, the initial sample should already meet all quality requirements. However, this is wishful thinking. As a rule, initial sampling is repeated until all quality requirements are met. Each adjustment interval requires a new initial sample test report when test production is restarted. All changes, whether improvements or deteriorations, must be precisely documented in this report so that they can be traced accordingly. The initial sample test report is therefore also valid for legal issues. In this context, the initial sample test report is also subject to a statutory retention period. This is based on Section 257 (1) HGB and Section 147 AO and is 10 years.
What does a complete initial sample test report include?
A complete initial sample test report includes a cover sheet with all data, the actual measurement report with all dimensions and at least one stamped drawing. It can also include an acceptance test certificate for raw material. Furthermore, a complete initial sample test report includes:
- Dimensional, material and functional test report
- Sample parts (5 pieces, for multiple molds 5 pieces per nest)
- Additional documents (e.g. process flow chart, production control plan)
- Prozessfähigkeitsnachweise, Messmittelfahigkeitsnachweise
- Werkstoffnachweise (Werkstoffzertifikat, ggf. Sicherheitsdatenblattel)
- All material data and details of the IMDS identification number on the cover sheet.
Depending on the order, either the forms of the valid VDA Volume 2 or the valid AIAG PPAP (Production Part Approval Process) must be used.
Deviations from the permissible tolerances must be noted in the test report. The required accuracy depends on the respective application and/or the specification of the parts. With regard to tolerances, the following applies: the measuring and test equipment uncertainty should not exceed a maximum of 10% of the smallest permissible tolerance of the measuring and test criteria. For example, if the smallest permissible tolerance may only be ±0.3 mm, the minimum accuracy of the measuring and testing equipment is 0.06 mm.
Information on the cover sheet of the initial sample test report
- Part designation and part number
- Any safety parts must be noted.
- The index of the component must be noted.
- The weight in kilograms.
- The current ID number
- Reason for the submission and the required submission level
The actual measurement report
The number of samples to be measured is noted in the actual measurement report. According to VDA, for example, this is 5 samples. If the test is successful, all items must be assessed as OK. In general, all parts must be measured separately for an initial sample test report. All position tolerances must be documented as position tolerances.
The materials report
The materials report contains, among other things, notes and information on
- Geometry, dimensional check
- Function test
- Materials testing
- Haptics test
- Acoustic testing
- Odor test
- Aussehenspüfung
- Surface inspection
- ESD testing
- Reliability check
- Approval of coating systems
- Other
Stamped drawings
Product-related, stamped drawings are also part of an initial sample test report. All product features, such as dimensions up to standards or specifications, as well as written product requirements such as the pore definition, surface definition, identification of the casting, etc. must be stamped. The stamping serves as numbering and at the same time allows the results to be clearly assigned.
All features must be clearly marked on the drawing with consecutively numbered item numbers.
What is the difference between an initial sampling including initial sample test report and a follow-up sampling?
A follow-up sampling is a repeated sampling of a product after the resumption of production. This can be the case, for example, after a production interruption lasting several months. Follow-up sampling is sometimes also referred to as reduced initial sampling. However, this is factually incorrect, as a follow-up sampling is never an initial sampling.
In general, the initial sample inspection report is an important factor for error-free and efficient production in industry and business. The focus is primarily on consistent quality in series production, which can be verified with an initial sample test report.
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