GM/FIAT IMDS INSTRUCTIONS - IMDS Information … · GM/FIAT IMDS INSTRUCTIONS March 11, 2003 - 1 -...

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Detailed instructions - IMDS

Date: 2003-03-11

Issue: Prel. 03

GM/FIAT IMDS INSTRUCTIONS

March 11, 2003

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Date: 2003-03-11

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Table of Contents

1. THE NEW ELV-DIRECTIVE......................................................................................................4

2. REQUEST TO SUPPLIERS .........................................................................................................4

3. TIMING REQUIREMENTS: DELIVERY OF DATA TO GM/FIAT.....................................4

3.1. USE OF INFORMATION:...............................................................................................................5 3.2. ACCEPTANCE/REJECTION OF IMDS DATA SUBMISSIONS: .........................................................5 3.3. ALTERNATIVE REPORTING.........................................................................................................5

4. PRIORITISED PROGRAMS .......................................................................................................6

4.1. EUROPE .....................................................................................................................................6 4.2. NORTH AMERICA.......................................................................................................................7

5. EXPLANATION OF PART/MATERIAL REPORTING REQUIREMENTS FOR GM/FIAT 8

5.1. EXPLANATION OF THE REQUEST FOR “ALL DATA” FOR GM:.......................................................8 5.2. NEW: CLARIFICATION OF GM SUBSTANCE LEVEL REPORTING REQUIREMENTS......................8 5.3. EXPLANATION OF THE REQUEST FOR “ALL DATA” FOR FIAT:......................................................9 5.4. DEFINITION OF A “COMPONENT/PART”......................................................................................9

6. CONFIRMATION FROM SUPPLIERS REFERRING TO THE LETTER IN JANUARY 2002 ..........................................................................................................................................................9

7. CASCADING OF IMDS-REPORTING TO SUB-TIER SUPPLIERS.....................................9

8. SUPPLIER INTERNAL COMMUNICATION REQUIREMENTS ......................................10

9. ..................10 CHANGES TO RESTRICTED/REPORTABLE SUBSTANCE DOCUMENTS

10. OBTAINING A COPY OF GMW3059 ..................................................................................10

11. IMDS - INTERNATIONAL MATERIAL DATA SYSTEM ...............................................10

11.1. ACCESS TO IMDS/ REGISTRATION / PASSWORD..................................................................11 11.1.1. How to logon to IMDS....................................................................................................11

11.2. SUPPLIER SUPPORT – IMDS ................................................................................................12 11.3. SUPPLIER TRAINING OPTIONS- IMDS..................................................................................12

12. SYSTEM PRESENTATION – IMDS/DECLARATION REQUIREMENTS FOR GM/FIAT...............................................................................................................................................12

12.1. SYSTEM OVERVIEW.............................................................................................................12 12.2. MAIN MENU ........................................................................................................................13 12.3. CREATE AN MDS / CREATE OPTIONS..................................................................................13 12.4. FOUR-STEP PROCEDURE TO INPUT THE DATA........................................................................14

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12.5. COMPONENT/MATERIAL COMPOSITION WITH BOM TREE STRUCTURE, INGREDIENTS...........15 12.6. INSERT THE TREE STRUCTURE OF AN MDS OR MODULE ......................................................16 12.7. COMMENTS ON MATERIAL LEVEL MDS’S...........................................................................17 12.8. SPECIAL SUBSTANCES “WILD CARDS / JOKER-SUBSTANCES ...............................................18 12.9. SPECIAL MDS: “FLAT BILL OF MATERIALS” (FBOM) FOR ELECTRONICS ........................19 12.10. RECYCLATE INFORMATION ..................................................................................................22 12.11. SUPPLIER DATA...................................................................................................................23 12.12. CAR MAKER RECIPIENT DATA.............................................................................................23 12.13. RECIPIENT – WHERE TO SEND MDS’S .................................................................................24 12.14. ADDITIONAL FUNCTIONALITY IN IMDS ...............................................................................25

12.14.1. Databases ...................................................................................................................25 12.15. MDS CHECK FUNCTION......................................................................................................27

13. CONTACTS – GM/ FIAT .......................................................................................................27

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1. The New ELV-Directive The European End-of-Life-Vehicles (ELV) Directive 2000/53EC that has been entered into force on October 21, 2000, imposes specific rules for materials used in cars.

• Art.4: prohibits the use of Pb, Cd, CrVI, and Hg (with exception of the cases listed in Annex II, updated July 2, 2002) in vehicles put on the market after July 1st 2003.

• Art.8: know the location of all hazardous substances (according to EU Directive 67/548) in vehicles when they are dismantled, available from October 2002 for each type of new vehicle put on the market.

• Art.7: recycling targets, 85% recyclability/ 95% recoverability: type approval will be requested by homologation authority from 2005 for both new type-approved vehicles and all new vehicles.

You as our Supplier are responsible to ensure that the ELV-Directive is fulfilled, and need to inform us about the contents of every part you deliver to GM/Fiat.

• Note: Even parts that contain items or materials that are presently exempted (in Annex II of the ELV-Directive) must be declared via IMDS.

2. Request to Suppliers Opel and Fiat have previously requested that their Suppliers enter data into IMDS. The current GM/Fiat letter, dated January 2002, requesting IMDS data, should be interpreted as a reminder to enter data for these Suppliers. For Suppliers to Saab, Vauxhall, GM North America Vehicle Operations, and Powertrain: The current GM/Fiat letter, dated January 2002, requesting IMDS data is a new requirement. • Note: Holden and GM do Brazil are not requesting that their Suppliers use IMDS at this time. Holden and

GM do Brazil Suppliers should continue to provide Material Data Sheets according to GMW3059 (appendix A)

2a. First time Submitters

For first time submitters to IMDS, GM offers a quick review for your first few data sheets. Please put in one or two sheets into IMDS and call the regional contact in section 13. The reviewer will prioritise your sheet so that you can use the first approved sheet as a template for the rest of your data sheets. This will reduce rejections (and re-work) both for the supplier and the GM reviewer.

3. Timing Requirements: Delivery of Data to GM/Fiat Clauses in GM/Fiat Letter Dated January 2002 Explanation of Clause 1: • The due date for this clause has now passed. Heavy metal declarations will no longer be accepted

• To provide all requested data concerning the composition of components for all ongoing new projects

including their carry over parts (e.g. the Epsilon program for OPEL / SAAB and Thesis, Stilo SW, Punto restyling for FIAT) supplied by your company and enter it into the IMDS no later than May 31st, 2002 or by PPAP. As of June 1st, 2002, suppliers to GM North American Vehicle Operations (GMNAVO) and North American Powertrain should have started using IMDS.

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Explanation of Clause 2:

This information is requested by GM/Fiat to ensure that the new vehicles will comply with the specification GMW3059 (GM) and Normative no. 9.01102 (Fiat) as well as the ELV-Directive 2000/53/EC requirements. • For GME parts that have not gone through PPAP: The IMDS Material Data Sheet (MDS) has to be submitted

electronically and approved. • For GME: The MDS’s for parts that are already PPAP’d had to be submitted electronically by May 31, 2002. • For GMNAVO/Fiat parts that will be going through PPAP: Material Data Sheets should have been submitted at

or before the PPAP date for review and approval starting in June 2002. GMW3059 Appendix A and STD 9.01102 annex CK paper forms will no longer be necessary. A one-year “grace” period for PPAP will be in effect while suppliers learn how to submit information into the IMDS.

All requested data concerning the composition of all other components supplied by your company should have been provided • To OPEL, VAUXHALL, SAAB, FIAT, or GME/Fiat Powertrain in the IMDS no later than September 30th,

2002. • To North America Vehicle Operations or North America Powertrain in the IMDS by:

- December 31st, 2002: For all parts on vehicles/powertrains exported to Europe. - December 31st, 2003: For all other current vehicles/powertrains other than European exports. Explanation of Clause 3: This request is for all of the parts, including spare parts that are supplied to GM/Fiat. • Chemicals that have been assigned a GM “FID” number (e.g. paints, adhesives, lubricants)

that are used in GM North America assembly plants are not included in this request.

Note: If you supply the same component to locations in Europe and North America, the European deadline for data submission applies.

3.1. Use of Information: Each Supplier entering information into IMDS acknowledges and agrees that such information can be used by GM/Fiat for any purpose relating to the ELV Directive, implementing legislation and regulations, as well as GM/Fiat's standard terms and conditions.

3.2. Acceptance/Rejection of IMDS Data Submissions: • GM: MDS sheets submitted to GM may be either accepted or rejected by GM. If GM accepts a MDS sheet,

it means that the data that has been submitted is of acceptable quality. Suppliers should not interpret acceptance of data to mean that the material composition of the part is acceptable under the ELV Directive (or other regulations).

• Fiat: Fiat will start using an automatic download (starting in July 2002). All data submitted to Fiat will be automatically accepted for download regardless of errors. If there is an error in a submitted MDS sheet, Fiat will send a separate e-mail to the supplier with a list of the mistakes for correction.

• Please see section 12.12 for the list of mandatory fields.

3.3. Alternative Reporting For Opel, Saab, Fiat and export parts for GM North America, it is extremely important to have 100% validation of these parts for compliance to the EU End of Life Vehicle Directive.

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If the supplier cannot input all of the information on Opel, Saab, Fiat and GMNA (export parts only) parts into IMDS by March 21, 2003, the supplier must fill out a compliance form by March 21, 2003. The compliance forms may be obtained from the regional contact in Section 13. These forms are also available on the GM supply power website, www.gmsupplypower.com.

4. Prioritised programs

4.1. Europe Vehicle programs, for the suppliers to give priority to, when reporting material constituents in IMDS: • Opel:

– All cars Model year 04

• Saab: – Saab 9-3 from Model year 03 – Saab 9-5 from Model year 03 – Carry over parts from Saab 9-5 Model year 02 that will be used in Saab 9-5 Model year 03

• Vauxhall: – Opel/ Vauxhall Frontera

• Fiat:

Model Version Engine Thesis LX 3000 24v V6

Stilo dinamic 1910 JTD 115CV 1596 mpi 16v

147 Distinctive 1910 JTD 115CV Barchetta Naxos 1747 mpi 16 v Spider/GTV Lusso 1979 16v TS Libra LX 1910 JTD 156 Progression 1910 JTD 156 Distinctive 1910 JTD Punto ELX 1242 MPI Ducato 14 q.li Cabinato 2800 JTD Ducato 10 q.li Furgone 1905 TD/2000 8v JTDMultipla ELX 1910 JTD Y Elefantino blu 1242 8v mpi 166 Progression 2400 JTD Doblo' Base 1910 DS / JTD Doblo' SX 1910 DS / JTD Marea ELX 1910 JTD 115CV Seicento SX 1108 mpi Palio WE 1910 DS / JTD Palio 2V 1242 mpi 8v Panda Young 1108 mpi Marengo 1910 JTD

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4.2. North America The following vehicle/powertrain programs exported to Europe should be inputted into IMDS. European Export Vehicles for the 2004 Model Year – Chevrolet Trailblazer (GMT360) – Cadillac CTS (GMX320) (D-car) – Chevrolet Corvette C5 – Cadillac XLR (GMX215) (Y-car) – Cadillac Seville (K-car) – Chevrolet Tahoe (GMT820) – Pontiac Montana (rebadged as the Chevrolet Transport) (GMT200) (U-Van) Additional European Export Vehicles for the 2005 Model Year – Cadillac STS (GMX295) – replacement for the Seville – Chevrolet Corvette C6 (GMX245) – replacement for current Corvette – Cadillac SRX/LAV (GMT265) The following 34 Vehicles will be going through PPAP in calendar year 2003. IMDS is a requirement for PPAP starting January 6, 2003. 2004 Buick Park Avenue (97PA) 2004 Cadillac SRX (GMT 265) 2004 U Van (GMT200 ) 2004 Pontiac Aztek (GMT250) 2004 Buick Rendezvous (GMT257) 2004 Cadillac SRX (GMT 265) 2004 GMC Equinox (GMT305) 2004 Hummer H2 (GMT345) 2004 Chevrolet Colorado/GMC Canyon (GMT355) 2004 Buick Raineer (GMT360) 2004 Chevrolet TrailBlazer/GMC Envoy (GMT360-370)2004 Isuzu Trooper (GMT370) 2004 Chevrolet/GMC B/C series (GMT560) 2004 Chevrolet T Series (GMT560T) 2004 Chevrolet Express/GMC Savana (GMT610) 2004 Chevrolet Silverado/GMC Sierra (GMT800) 2004 Grand AM, Chevrolet Malibu, Alero (GMX130) 2004 Impala, Monte Carlo (GMX210-230) 2005 Cadillac XLR (Roadster) (GMX215) 2004 Buick Lesabre (GMX220) 2004 Chevrolet Corvette (GMX245) 2004 Cadillac Deville (GMX270) 2005 Cadillac STS (GMX295) 2004 Cadillac CTS LHD, RHD (GMX320) 2004 Cadillac CTS (GMX 320V) 2004 Saturn ION Coupe (GMX 357)

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2005 Buick Regal (GMX365) 2004 Buick Century (GMX365) 2004 Pontiac Grand Prix (GMX367) 2004 Chevrolet Mailbu (GMX 380) 2005 Pontiac Grand AM (GMX381) 2004 J-Cavalier, Sunfire 2004 Saturn LS MCE 2004 Chevrolet Astro/GMC Safari

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Parts lists are available on request for all of the above GMNA PPAP and export vehicles.

5. Explanation of Part/Material Reporting Requirements For GM/Fiat

5.1. Explanation of the request for “all data” for GM: Each component and all of its parts have to be specified within IMDS as a complete tree structure that represents the actual build of the final component. Each level (component, Semi-component, material, chemical substances) of the tree structure must be inserted in the Material Data Sheet (MDS).

Certain components may be input using the Flat Bill of Material (FBOM) approach if this is easier for the supplier. Presently, electronic circuit boards and wiring harnesses have approved FBOM formats. (See section 12.9: Special MDS: “Flat Bill Of Materials” (FBOM) for Electronics). Additional FBOM approved by the IMDS Steering Committee are also acceptable. For all parts in IMDS, GM must determine whether these parts are compliant with the ELV Directive. So if you have a lead, mercury, hexavalent chromium or cadmium part, and it fits under one of the exemptions in the directive, please note that you must detail the component, material and substance level so the GM reviewer can determine compliance.

5.2. NEW: Clarification of GM Substance Level Reporting Requirements For thermoplastic/thermoset materials: GMW3059 restricted/reportable substances must be declared (listed as a basic substance in the tree structure), as well as the base polymer and fillers/reinforcing materials (if the sum of fillers/reinforcing materials is greater than 5%). The remaining substances (to sum up to 100%) shall be input using the “Misc” substance. However, it is acceptable for a supplier to send additional information at the substance level if the supplier chooses to do so.

• For all other materials: GMW3059 restricted/reportable substances must be declared (listed as a basic

substance in the tree structure). The remaining substances (to sum up to 100%) shall be input using the “Misc” substance. However, it is acceptable for a supplier to send additional information at the substance level if the supplier chose to do so.

• Whenever misc or other jokers are used in a MDS, you must declare that the material in the MDS is in

compliance with GMW 3059 and VDA 232-101 guidelines. There are two places to put this.

• At the Materials section under remarks by declaring the following statement. “The formula of this material doesn’t have any restricted or reportable substances according to GMW3059 and VDA 232-101 guidelines.” This is the preferred place for declaration. For Tier 2 suppliers, e.g., for a material supplier, if its MDS is to be used (uploaded) by other tier 1 suppliers, the declaration statement must be posted at the Materials section under remarks. It is the only way that OEM can view the declaration statement in the MDS created and submitted by Tier 1 suppliers.

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• For a MDS that has numerous nodes, especially for those MSDs that contain information from several tier 2 and tier 3 suppliers through uploading, you may make the following declaration at the Recyclate Information section under comment: “There are no any restricted or reportable substances according to GMW3059 and VDA 232-101 guidelines in any materials used in this part except those declared in the MDS.

5.3. Explanation of the request for “all data” for Fiat: Each component and all of its parts have to be specified within IMDS as a complete tree structure that represents the actual build of the final component. Each level (component, Semi-component, material, chemical substances) of the tree structure must be inserted in the Material Data Sheet (MDS).

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Certain components may be input using the Flat Bill of Material (FBOM) approach if this is easier for the supplier. Presently, electronic circuit boards and wiring harnesses have approved FBOM formats. (See section 12.9: Special MDS: “Flat Bill Of Materials” (FBOM) for Electronics). Additional FBOM approved by the IMDS Steering Committee are also acceptable.

For materials with high know how Fiat accepts the use of jokers (i.e. "further additive"), amount of 10% maximum (higher rates have to be agreed to by the Fiat Engineering Department).

For other materials Fiat requires the declaration of all substances contained above a threshold value of 0.1% (or otherwise specified in STD 9.01102). The use of confidential flag is accepted up to 5 higher rates have to be agreed to by the Fiat Engineering Department). Temporarily, Fiat also accepts jokers for materials and components that are not available during the data collection (e.g. the joker substance >not yet specified<)

5.4. Definition of a “Component/Part” Any item that is supplied directly to GM/Fiat by a Tier 1 supplier that is assigned a unique GM or Fiat part number and ends up being used on a vehicle.

MDS’s generated by sub Suppliers must be sent directly to the same company that the actual component is supplied to. MDS’s generated by GM/Fiat’s Tier 1 Suppliers are then sent to GM/Fiat (see also Section 12.14: Recipient – Where to Send MDS’s).

6. Confirmation from Suppliers Referring to the letter in January 2002

The deadline for supplier to register their receipt of the letter, in the website http://www.eds-thn.nu/imds has passed. This webpage has been deleted.

7. Cascading of IMDS-reporting to Sub-tier Suppliers It is the responsibility of Tier 1 Supplier to cascade this information and all requirements to all sub-tier Suppliers and ensure that all of their sub-tier Suppliers comply with the same requirements. It’s also the Tier 1 Suppliers responsibility to make sure that submission of the requested material content is carried out.

The Tier 1 supplier can decide what method they wish to use to collect the part/material/substance data from their supply chain. Sub-tier suppliers must supply data to the Tier 1 in any format that is specified by the Tier 1 supplier.

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8. Supplier Internal Communication Requirements Please cascade this information package to the appropriate department managers in your organization. - Product development - Quality Manager - Manufacturing - Health, Safety and Toxicology - Purchasing - Information Technology - Materials Engineering - Sales - Corporate Environmental/ - GM/ Fiat Account Manager/ Business Unit Regulation Staff

9. Changes to Restricted/Reportable Substance Documents The following documents will be modified to include IMDS: • GMW3059 (Opel, Saab, Vauxhall, GM North America Vehicle Operations, Powertrain)

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GMW3059 has been modified to match the new system requirements (IMDS). Include the final declarations via IMDS during the product development process.

• Normative Number 9.01102, attachment CK (Fiat)

Modification of the attachment CK, in Normative number 9.01102, to match the new system requirements (IMDS). This standard has been modified to conform to GMW3059. To relate the Production Approval (by VDDP) to the availability and correctness of the information inserted in the system.

10. Obtaining a Copy of GMW3059 GM/Fiat restricted/reportable substance documents are updated yearly to reflect changes in substance regulations worldwide. (Please check if you have the latest available version by contacting IHS.) If you do not have a current copy of GMW3059 ”Restricted and Reportable Substances for Parts” you may purchase it from • IHS (Information Handling Service Group)

Homepage IHS: http:/global.ihs.com

• Telephone no. IHS – local IHS Nordic countries: + 45 3940 2244 IHS Germany: + 49 89 895 2690 IHS Italy: + 39-06-4786-833 IHS United States: + 1-303-397-7956 IHS Canada: + 1-613-237-4250

Additional information on GMW3059 is available on www.GMW3059.com

11. IMDS - International Material Data System

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The IMDS system has been designed jointly by a German carmaker’s consortium and EDS, a leader in Information Technology systems.

• In order to ensure regulatory compliance to the ELV-Directive and any applicable substance regulations over time, it is necessary to document the material and substance composition of the entire vehicle.

IMDS allows the OEM’s and the Suppliers to collect and to manage the information regarding the material and substance composition of all the components of a vehicle so that compliance to the ELV- Directive is documented.

11.1. Access to IMDS/ Registration / Password

On the public pages of www.mdsystem.com, you can find general information such as system requirements, training courses calendar, and automotive news etc. A company account, user name, and personal password are required to access IMDS. If your company is not already registered in IMDS or needs additional user ID/Passwords: • The registration form and additional information concerning the registration are available at the public pages

at IMDS website www.mdsystem.com, link: System.

• Information concerning the different available user profiles is located in the registration form.

• Send your registration form to: [email protected] or [email protected]

• EDS will return a mail containing the necessary user-information to access IMDS.

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IMDS Password Tips: NEW!! Passwords must be changed every ninety days or you will have to contact your company Client Manager to reactivate your password.

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After three attempts of typing a wrong password the system disables it. Contact EDS Help desk to reactive your password. Make sure to use the menu options within the IMDS. Closing a window incorrectly in IMDS may lock you out of the system for a period of time.

11.1.1. How to logon to IMDS There are two ways to login to the IMDS: 1. From the IMDS Welcome page: www.mdsystem.com <SYSTEM LOGIN> 2. From the IMDS Welcome page: Use the link <Public IMDS pages>, <SYSTEM>, <SYSTEM ACCESS> Both of these alternatives open up the IMDS System Access window.

Click on <LOGON> Enter your IMDS User ID and password Click <LOGON>

These steps will take you to the Main Menu Screen.

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11.2. Supplier Support – IMDS

The IMDS help desks are available to answer questions concerning the functionality of the IMDS.

• HELP DESK - GERMANY: From 8 AM to 4.30 PM E-mail: [email protected] Phone no. +49 (0) 421 5256-666

• HELP DESK - ITALY: From 9 AM to 6.30 PM E-mail: [email protected] Phone no. +39 (0) 80 3853116

• HELP DESK - NORTH AMERICA: From 8 AM to 5 PM (eastern time) E-mail: [email protected] Phone no. +1 248 267 3460

11.3. Supplier Training Options- IMDS Training courses - IMDS: • One day training courses are arranged by EDS (cost approx. 400 EURO), in Germany, Italy, Spain, Great

Britain, and Czech Republic. The course enrollment must be requested by contacting the IMDS help desks o The calendar and locations for the training events is available on the IMDS public page,

www.mdsystem.com, link: Training •

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For North America, MDS Map offers IMDS training services. Contact Chris Harden (734-213-5088) or [email protected].

Training on line - IMDS:

An e-learning course is available via the IMDS web site (cost approx. $200), to get to know the IMDS application. The interactive online training for IMDS is in English

Training individually

EDS offers in-house courses on request. MDS Map offers an instruction manual that explains how to input data into IMDS. Contact Malcom Fox ([email protected]) or visit the MDS Map website (www.mdsmap.com). MDS Map also offers other IMDS services.

12. System Presentation – IMDS/Declaration requirements for GM/Fiat

12.1. System Overview When logged on to IMDS, you will see this menu, the main menu:

http://www.mdsystem.com/

mailto:[email protected]

http://www.mdsmap.com/

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12.2. Main Menu The alternative selections are:

• Create: Create a new, complete MDS (Material Data Sheet) or a Module (for internal use) for a Component, Semi-component or a material.

• Search: Search for MDS’s or Modules for components, semi-components, materials or search for basic

substances.

• Analysis: IMDS allows the user to analyse the data contained in the MDS’s.

• Sent: Allows the user to see MDS’s that have been sent to external recipients.

• Received: Allows the user to see MDS’s that have been received from external suppliers.

• Messages: View messages received by your company.

• Log off: Exit the password-protected area of IMDS and return to the public pages.

• Follow Up: Under the menu “Received” the users can assign an MDS of any status except 'not browsed yet' to a follow-up list. For each MDS the users may enter a comment and reminder date. This follow-up entry is visible to all users having access to the received MDS. By this date the users will be reminded via IMDS-Message on checking this specific MDS. In addition a list of all Follow-Up entries can be seen under menu item 'Follow-Up'.

• Recommendations: The data entry recommendations published by the car manufacturers are available

under this menu.

12.3. Create an MDS / Create Options To create an MDS or a module, click on the link: create.

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• It is possible to create Material Data Sheets (MDS’s) according to the following structures: Explanation of the alternative create options:

Component: It is the main structure. Here components or assemblies must be inserted. Only MDS’s generated by GM/Fiat’s Tier 1 Suppliers must sent to GM/Fiat.

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Semi-component: Semi-components differ from components because their exact dimensions (or weight) are not specified. Use a Semi-component when the product you supply must be modified further prior to achieving the final form it would have in a vehicle. Examples of Semi-components are: coils of steel (parts are stamped out of the coil), coils of wire (cut to final lengths for use in the vehicles).

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NOTE: Paints, greases, adhesives (etc.) can be treated as a material or Semi-component. However, GM prefers that they be treated as a material.

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- For these kinds of materials, the composition of these materials must be reported for the composition of the cured material as it remains on the vehicle, not the complete composition of the paint prior to its application on the vehicle. Example: For paints, only the cured portion that remains on the vehicle must be reported (not the solvent content).

- Note also that flame-retardants are treated as a material in IMDS.

Material: If a material cannot be found in the material database within IMDS, this option must be used to create the material MDS for further use in an MDS of a component or an assembly

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A Substance should always be attached to a material. It is not allowed to attach a substance to a Component or Semicomponent. Substance are subdivided into four different ‘substance levels’

1. Basic Substances / Constituents 2. Declarable Substances 3. Confidential Substances 4. Highly Confidential Substances (know-how relevant)

NOTE: For more information please look at the Recommendation IMDS 001 which is available at the IMDS website and see clause 12.7. When creating an MDS of a component or assembly it is essential that the structure tree represent the actual component or assembly and that information is inserted on each level, component, Semi-component, material and substance (as shown in the lamp example). (See section 5: Explanation of Part/Material Reporting Requirements for GM/Fiat.) The only exception to this structure is on parts/components that may be reported in the FBOM format. (See section 12.9: Special MDS: “Flat Bill Of Materials” (FBOM) For Electronics)

12.4. Four-step procedure to input the data To create an MDS for a component, Semi-components or a material there is a four-step procedure to input the requested data.

o Component/Material composition with BOM tree structure, Ingredients. o Security/Environment information o Supplier data

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o Car Maker Recipient data

• Language used in IMDS English must be used as standard language in IMDS. All names/terms of component/Semi-components/material/chemical content shall be written in English, comments etc. shall be written in English. Create screen:

12.5. Component/material composition with BOM tree structure, Ingredients.

In the ingredients menu, the tree structure that represents the component has to be inserted. It is essential that information for each of the levels - component, Semi-component (if any), material and chemical substances are included.

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• The tree structure allows suppliers to attach MDS’s that have been submitted to them by sub suppliers.

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12.6. Insert the tree structure of an MDS or Module The following buttons are used to create the tree structure of a MDS for a component:

Create directly a component in the MDS – The components name, part no. and weight shall be inserted.

Create directly a Semi-component in the MDS – The Semi-components name, part no. shall be inserted.

Is used to search for a material in the material database within IMDS. The material shall be inserted under the component-/Semi-component level.

Is used to search for a substance in the substance database within IMDS. Substances shall be inserted under the material level when creating an MDS of a material.

Is used to search for an already existing MDS of a sub component in the IMDS database, either self-made or from a sub-supplier.

Is used to delete a node in the structure tree.

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12.7. Comments on Material Level MDS’s

If, after searching, a material is not available in the IMDS system, a material level MDS must be built prior to creating the component MDS. The material MDS can then be imported into the component MDS. A material MDS is built using the same concept that is used to build a component MDS.

Ask the raw material supplier for the required substance composition information to meet the GM/Fiat requirements. The information contained in a Material Safety Data Sheets (MSDS) may not be sufficient for these reporting requirements.

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Warning: It is necessary to refer to substances or basic components when building an MDS for a material in the IMDS. - Metal compositions (e.g. steel): Fe, Cr, Ni etc. - Plastic compositions (e.g. PVC): PVC, plasticisers (i.e. DOP) stabilizers, etc. (It is incorrect to insert elements like C, H Cl.)

•

Material MDS Detail Screen:

Material (MDS) Detail Screen Field Descriptions: • Material name: acc. to existing Standards, e.g.:

- steel, iron -> EN 10027, GM6409M, GMW2M-ST-S - plastics -> ISO 1043 - elastomers -> ISO 1629

• Trade name: Product trade name (usually applicable for plastics) • Material No: applicable for steel, iron according to EN 10027 (e.g. 1.4243) • Symbol: (applicable for plastics): the recycling symbol is based on ISO 1043 (e.g. >PA66-GF30<)

Classification: Material classification based on the VDA 231-106 (German) standard • Norms/Standards: Applicable Industry Standards (e.g. EN 10027, SAE J405) • In-house Norms: Applicable OEM standards for materials (e.g. GMW4, QS 13MO00, GM12M) • Supplier: The name of the material supplier (e.g. Thyssen, BASF, General Electric) • Remarks: any additional comments that the user might wish to add to the MDS

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• •

•

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12.8. Special Substances “Wild Cards / Joker-substances IMDS contains some wildcard (or “joker”) substances. Since GM only requires GMW3059-substances (F or D) to be reported at the substance level, a joker can be used to fill the remaining portion of substances (the system require 100% accounting for substances in a material).

GMW3059 substances (F or D) must be reported at the substance level. The GM preferred joker for substance reporting once GMW3059 substances have been reported is the “Misc.” joker. Suppliers might wish to use other jokers for specific circumstances. Other acceptable jokers are listed in the IMDS Recommendation IMDS001.

• See section 5.3 for Fiat joker information. • Concerning Request/Hg/Cr6/Cd/Pb, do not use this Joker for GMNA. Do not use for Saab, Opel and Fiat

after July 2003. • Whenever misc or other jokers are used in a MDS, you must declare that the material in the MDS is in

compliance with GMW 3059 and VDA 232-101 guidelines. There are two places to put this.

1) At the Materials section under remarks by declaring the following statement. “The formula of this material doesn’t have any restricted or reportable substances according to GMW3059 and VDA 232-101 guidelines.” This is the preferred place for declaration. For Tier 2 suppliers, e.g., for a material supplier, if its MDS is to be used (uploaded) by other tier 1 suppliers, the declaration statement must be posted at the Materials section under remarks. It is the only way that OEM can view the declaration statement in the MDS created and submitted by Tier 1 suppliers.

2) For a MDS that has numerous nodes, especially for those MSDs that contain information from

several tier 2 and tier 3 suppliers through uploading, you may make the following declaration at the Recyclate Information section under comment: “There are no any restricted or reportable substances according to GMW3059 and VDA 232-101 guidelines in any materials used in this part except those declared in the MDS.

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• Available joker-substances in the IMDS:

Note: When searching for a joker-substance, input >system< in the CAS-no field.

12.9. Special MDS: “Flat Bill Of Materials” (FBOM) For Electronics An FBOM is a material data sheet or a part of a material data sheet that has a flat internal structure (MDS does not have the complete structure of each and every component). The only required information is the declaration of the materials and substances included within the part. Suppliers of certain types of parts are given the option to declare according to “Flat Bill Of Material”.

•

•

The use of “Flat Bill Of Material” presently applies to parts such as electronic modules, wiring harness modules, and electric motors. When using the “Flat Bill Of Material” the suppliers are requested to report the total amount of materials and substances, according to GMW3059 and Normative no. 9.01102, used in the components. There is no need to delineate the component/Semi-component structure of the modules. The reporting is based on how much total aluminum, polycarbonate, lead, etc. is in the modules, not how much in each resistor or capacitor.

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Example: FBOM for Wiring Harness

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Example: FBOM for Circuit Board Circuit board or Electronic motor - Example

Metallic Materials Steel Cu Alloys … Soldering alloys Sn

Pb…

Misc. Plastics Polyester

Epoxy Resin

Polypropylene … Misc.

Butadiene Elastomerics

Rubber, natural …

Misc.

Silicon Others

…

Misc.

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12.10. Recyclate Information Suppliers are required to report the amount of recycled content plastics (by weight percent of the GM part), in question 1. Questions 3 and 4 are optional. Explanation of questions 1-4:

1 What is the amount of recycled content plastics (by weight percent of the GM part). 2. What is the actual recycled plastic content in the part. 3. How much of the recycled plastic content comes from post-industrial waste sources (per part weight). 4. How much of the recycled content comes from post consumer waste sources (per part weight).

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12.11. Supplier Data Input the name of the employee who is responsible for sending the MDS to GM/Fiat.

12.12. Car Maker Recipient Data The following recipient data must be inserted when sending MDS’s to GM/Fiat:

Example of data input, mandatory data.

DUNS no. or Fiat Supplier Code

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Explanation of mandatory fields: • Part/item No: For GM, input the GM-part number of the part/assembly. For Fiat, input the drawing number.

The part number is a seven or eight digit number, with no dashes, spaces or letters.

• Part Description: Input the official English name of the part as described on the GM drawing. Use a description that will make sense to the GM reviewer (e.g. Bolt, A-pillar trim assembly, not 12756D. If your part is a prototype or a service part, then put in word “service” or “prototype” in parenthesis after the name.

• Drawing No.: Input the GM/Fiat-drawing number, if available. (The drawing number may be different than the part number.)

• Drawing dated: Input the date of release of the current revision of the drawing. • Drawing Change Level: Input the current version/level of the drawing. • Supplier Code: Input the supplier code, for:

GM: The requirement is the manufacturing DUNS number. The DUNS number is a nine-digit number. Do not use spaces, dashes, or letters. Fiat: Supplier code.

• Material level: Input the material information for every component part. Need suppliers, trade names, and symbols for plastics.

• Basic Substances: The basic substance level (blue triangle) level must be attached to a material (2 green dots), not directly to a component or semi-component. Failure to do this results in the “Analysis based on material” to not add up to 100%. If a joker is used, you must add the GMW3059/VDA statement as noted on page 6.

12.13. Recipient – Where to send MDS’s Material Data Sheets can be: • Send - When there is one only recipient. • Propose - When there are many recipients. • Internal - For internal use. • Publish - When the Data Sheet has to be visible for everybody - useful to insert new materials. Suppliers should send the MDS to the division of GM or Fiat that is (or was) responsible for PPAP, even if the part will be (or is) used by other divisions within GM or Fiat. This applies whether the parts are new parts, parts under development, or carryover parts (parts that have already been PPAP’d). (Example: If Saab is responsible for PPAP and the part will be/is used by both Saab and Opel, the MDS shall be sent only to the Saab account in IMDS.) • Note: This information is available from your Quality (or other) organization that handles the PPAP

submissions for your company. • Note: The Account for GMNA is split. Please send the Powertrain parts (engines/transmissions) to

powertrain and the Vehicle Operations (all other parts) to GM NA Vehicle Operations.

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List of GM/Fiat Accounts in the IMDS System: General Motors- NA Vehicle Operations (includes GM Mexico)

(IMDS Company ID# 5751)

General Motors- NA Powertrain (IMDS Company ID# 5754) General Motors Strasbourg (IMDS Company ID# 3949) Adam Opel AG (includes GM Portugal and Vauxhall)

(IMDS Company ID# 104)

Saab Automobile AB (IMDS Company ID# 303) Saab Automobile Powertrain AB (IMDS Company ID# 15534) Fiat Auto (IMDS Company ID# 1316) NOTE: There is no account for GM do Brazil (South America) or Holdens. Suppliers must still submit GMW3059 Appendix A Forms to these locations.

12.14. Additional functionality in IMDS

12.14.1.Databases Within IMDS there are several databases to support the data sheets preparation. The most significant are: • Substances: This is the list of the elementary substances with the related CAS number.–The IMDS system

contains the VDA List of Declarable Materials, which is a list of substances that has been generated by the German automotive industry. This directory contains approximately 400 substances, which are subdivided into two categories: “prohibited” and “declarable”. –The prohibited substances and the substances that require declaration are red-marked when they are included in an MDS.

• Materials: The input of Material MDS’s by the Material Suppliers, are very important to get a good quality of the data in the material database –The Material Supplier should publish their Material MDS’s, instead of sending it to one customer only so the part supplier is able to reference published Material MDS’s –To create an Material MDS, the substances in the database shall be used. If a substance is found to be missing in the database, contact EDS help desk and they will update the database.

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Basic Substance List

Material Database

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12.15. MDS Check Function Before sending an MDS, the system executes a check of the correctness and thoroughness of the input data. The system will check to make sure that all mass information balances at every level of the MDS.

• If masses don’t balance, check the mass value of any heavy items that could have been input with commas (North American thousands delimiter). The IMDS system will change a number input with a comma into a decimal point. (EG: A number input as 5,000g will be converted to 5.0g)

It is possible to execute a check of input data during the development of an MDS sheet by using the following menu:

13. Contacts – GM/ Fiat Opel:

Antje Heymann Adam Opel AG TEZ T&V Zentrallabor Spezifikationszentrum IPC 85-70 D-65423 Rüsselsheim Germany Phone: +49-6142-7-71710 Fax: +49-6142-7-61745 E-mail: [email protected]

Dr. Ralf Langendorf Adam Opel AG ITEZ T&V Zentrallabor Organische Werkstoffe D-65423 Rüsselsheim Germany Phone: + 49-6142-7-766268 Fax: + 49-6142-7-74484 E-mail: [email protected]

Vauxhall: Peter Stoker or Peter Woodcock, Special Studies, Vauxhall Engineering Centre, Station Lane, Millbrook Bedford, MK45 2YL England Phone: +44 1525 842519 Fax: +44 1525 842501 E-mail: [email protected]

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SAAB: Marilis Lepik Environmental Concerns Materials A16-1 TVLE Saab Automobile AB SE-461 80 Trollhättan Sweden Phone: +46 (0) 520 852 06 Fax: +46 (0) 520 781 50 E-mail: [email protected]

Maria Axsäter Environmental Concerns Materials A16-1 TVLEE Saab Automobile AB SE-461 80 Trollhättan Sweden Phone: +46 (0) 520 48 34 17 Fax: +46 (0) 520 781 50 E-mail: Maria.axsä[email protected]

Fiat: Claudia Berruti Fiat Auto S.p.A. D.I.P.-Laboratories Materials Engineering C.so Settembrini, 40 - 10135 Turin Italy Phone: + 39 11 6835564 Fax: + 39 11 6838092 E-mail: [email protected]

Riccardo Boggio Fiat Auto S.p.A. D.I.P.-Laboratories Materials Engineering C.so Settembrini, 40 - 10135 Turin Italy Phone: + 39 11 6835714 Fax: + 39 11 6838092 E-mail: [email protected]

GM North America: Doris Hill General Motors Corporation Design for the Environment MC 483-520-251 2000 Centerpoint Parkway Pontiac, MI 48341-3147 USA Phone: +1248 753-0220 Fax: +1 248-753-0269 E-mail: [email protected]

Edward Becker General Motors Corporation- Powertrain Materials Engineering MC 483-710-251 895 Joslyn Ave. Pontiac, MI 48340 USA Phone: +1 248-857-2129 Fax: +1 248-857-2599 E-mail: [email protected]

GM/FIAT IMDS INSTRUCTIONS - IMDS Information … · GM/FIAT IMDS INSTRUCTIONS March 11, 2003 - 1 -...

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