TV-02023-EN - V15-Technical Cleanliness Requirements - 2023-03-06

Technical Specification TV – 02023-EN
Title Technical cleanliness requirements for components and assemblies of vehicle steering systems
Content
1. Foreword ................................................................................................................................................... 3
2. Informative elements ............................................................................................................................... 3
2.1. Functional responsibility, contacts .......................................................................................... 3
2.2. Revisions............................................................................................................................. 3
3. Purpose of this technical specification .................................................................................................. 5
4. Scope/Validity ........................................................................................................................................... 5
5. Terminology .............................................................................................................................................. 5
6. Responsibilities ........................................................................................................................................ 5
7. Cleanliness requirements entered on drawing ...................................................................................... 6
8. Test planning – Timing of test – Reaction plan – Root cause analysis ............................................... 7
8.1. Pre-production phase ........................................................................................................... 7
8.2. Sampling for production/Initial sampling ................................................................................. 7
8.3. Initial sampling..................................................................................................................... 8
8.4. Inspection by external laboratories ......................................................................................... 8
8.5. Series delivery to the customer .............................................................................................. 8
8.6. Incoming inspection of supplier parts ...................................................................................... 9
8.7. Reaction plan for limit value exceedance ................................................................................. 9
8.7.1. Single inspection ......................................................................................................... 9
8.7.2. Triple inspection .......................................................................................................... 9
8.7.3. Reaction plan in the event of limit values being exceeded in a re-examination................... 10
8.7.4. Root cause analysis/Further analysis ........................................................................... 10
9. Preparations for cleanliness testing ..................................................................................................... 12
9.1. Testing method .................................................................................................................. 12
9.2. Definition of cleanliness classes ........................................................................................... 12
9.2.1. Particle size classes ................................................................................................... 12
9.2.2. Cleanliness classes SK I to SK VI ................................................................................. 12
9.3. Definition of particles and burrs ............................................................................................ 13
10. Cleanliness testing ................................................................................................................................. 14
10.1. Cleanliness requirements on the component/assembly ........................................................... 14
10.2. Control surface and number of the component/assembly to test .............................................. 14
10.3. Part removal, part handling and transport of the test samples.................................................. 14
Ausdruck ist unkontrolliert und dient zur Referenz. / Printout is uncontrolled and is only for reference.
TV-02023-EN, Version: 15 Ersteller / Author : Nicole Reitz, Christoph Hutzler Seite / Page 1/29
10.4. Requirements on materials and equipment used .................................................................... 14
10.4.1. Test fluid: ................................................................................................................. 15
10.4.2. Testing facility:.......................................................................................................... 15
10.4.3. Test equipment ......................................................................................................... 15
10.4.4. Analysis filter/membrane............................................................................................ 15
10.4.5. Filter occupancy ........................................................................................................ 16
10.4.6. Maintenance and calibration of the test equipment ........................................................ 16
10.4.7. Measurement analysis system .................................................................................... 16
10.5. Determination of blank value ............................................................................................... 16
10.6. Qualification tests (decay behavior)/Validation of testing method.............................................. 18
10.6.1. Decay measurements: ............................................................................................... 18
10.6.2. Start parameters for the decay analysis ....................................................................... 20
10.6.3. Decay criterion ≤10% ................................................................................................ 20
10.6.4. Impermissible decay tests .......................................................................................... 21
11. Component/assembly cleanliness testing ........................................................................................... 22
12. Archiving the filter membranes............................................................................................................. 22
13. Packaging cleanliness testing ............................................................................................................... 23
13.1. Quick cleanliness testing of direct packaging ......................................................................... 23
13.2. Quick cleanliness testing of indirect packaging ........................ Fehler! Textmarke nicht definiert.
13.3. Adhesive tape test and particle stamps ................................................................................. 23
14. Inspection of the environmental cleanliness ....................................................................................... 23
15. Confirmation of technical cleanliness over product lifetime .............................................................. 24
15.1. Pre-series confirmation ....................................................................................................... 24
15.2. Series confirmation............................................................................................................. 26
16. Documentation of component/assembly and packaging cleanliness ............................................... 28
17. Related documents................................................................................................................................. 29
Remark concerning document language
The interpretation of the German edition is binding.
1. Foreword
The task of technical regulations is standardization. The scope is to create a simple, consistent and
comparable way to measure the technical cleanliness of components and assemblies.
The TV is the basis for every project. Any deviation must be discussed with the relevant department of
ThyssenKrupp Presta Steering. A written confirmation of the approval for the deviation by the relevant
department and the project manager is mandatory.
2. Informative elements
2.1. Functional responsibility, contacts

The functional responsible contacts are located in the department technical cleanliness in plant Mülheim and
Eschen.
2.2. Revisions
Revision Date Section Brief description Name
1.0 Index A 13.01.2010 Dr. Peter Sowa;
First revision
Renate Bröer
1.0 Index B 05.10.2010 Dr. Peter Sowa;
Technical specification extended from electric steering systems to vehicle steering Renate Bröer
systems
2 21.07.2011 Dr. Peter Sowa;
Layout updated, content unchanged
Renate Bröer
3 08.11.2011 Addition of section "Proof of capability" Dr. Peter Sowa
4 23.05.2012 Dr. Peter Sowa
Proof of capability for parts with <H> and <K>features
proof of short-term capability is part of the initial sampling process
5 12.11.2013 Christoph Apel
addition of max particle size for blank values if cleanliness requirements or cleanliness
level of samples are unknown
addition of recommended test fluid “G 60 Spezial-Industrie-Entfetter”
layout customization of various numberings and formatting
6 04.03.2014 Christoph Apel
changing scope of TV to: Presta/Steering Gear
7 13.07.2015 Nicole Reitz
“SteerTec” removed and integrated the English Version
8 28.03.2017 Updated in regards to VDA 19.1 (2015) Nicole Reitz
English version removed and transferred to a separate document

Removed: chapter "Wiping test"
Cleanliness classes expanded
9 08.05.2018 SK-table corrected, table blank value inserted Nicole Reitz
10 17.06.2019 scope increased Nicole Reitz
11 02.12.2019 scope increased and cleanliness class SK2.5 added Nicole Reitz
12 11.12.2020 completely revised edition Nicole Reitz
13 Jan 23 no changes in content Nicole Reitz
14 17.01.2023 Nicole Reitz
Added: Annex "Additional requirements for BMW products regarding technical
cleanliness"
15 06.03.2023 Layout and formatting changed Nicole Reitz,
Christoph Hutzler
7 Added: requirements on drawing entry for BMW products, requirement classes
Added: "green" status for initial sampling only after proof of cleanliness including
8.2
transport influence
8.4 Added: testing by external laboratories

Added: requirement of internal laboratory for <H> and <K> characteristics
8.6 Changed: Table 1 - Increase in test frequency for <K> characteristics
Added: <H> and <K> characteristics - after limit violation 6 weeks increased test
8.7.2
frequency
8.7.3 Added: reaction plan for limit violations in a verification

8.7.4 Added: root cause analysis/further analysis
Added: process diagram for limit violations
9.2.2 Added: modification of cleanliness classes including example (figure 4)
9.3 Added: definition of particles and burrs
10.3 Added: part removal, part handling and transport of the test samples
10.4.3 Added: Flatbed scanners not permitted
Added: recommended equipment
10.4.4 Added: drying of filter membranes after extraction
10.4.6 Added: maintenance and calibration of test equipment
10.5 Added: blank value when doing several analysis of one part number, process diagram
10.6.1 Added: decay test must be carried out with same extraction method
Added: blank value before and after decay test
10.6.2 Added: starting parameters for decay test
11 Added: rounding rules
12 Added: archiving
13 Removed: visual examination
13.3 Added: particle stamps
14 Added: inspection of environmental cleanliness
15.1 Changed: short-term capability into pre-series confirmation
Added: 10% rule, documentation in FS-12319
15.2 Changed: long-term capability into series confirmation
Added: 10% rule, documentation in FS-12319
3. Purpose of this technical specification
This technical specification describes the cleanliness requirements for assemblies and components used in
vehicle steering systems of ThyssenKrupp Presta Steering and its suppliers, as well as the procedure for
cleanliness analyses in the as-delivered condition.
It also defines cleanliness requirements for packaging materials. In addition, this technical specification sets
out the tasks and duties involved in verifying component cleanliness in the pre-production, sampling, and
production phases and describes the verifications required and how they should be documented. The
specification is based on VDA 19.
4. Scope/Validity
The technical specification applies to all steering system sub-components, components and assemblies for
which this technical specification is indicated in the drawing. This technical specification should be treated with
the same care and confidentiality as the associated drawing. It may not be passed on to third parties without
the prior consent of ThyssenKrupp Presta Steering.
5. Terminology
Sub-component: Individual, no longer dismountable component of a unit.
Component: Components can consist of several sub-components.
Assembly: Several individual components combined in one unit.
Inspection lot: An inspection lot consists of several components (see chapter 10.2)
Cleanliness class: Cleanliness requirement predefined by ThyssenKrupp Presta Steering (containing
cleanliness levels)
Test liquid: Medium used in cleanliness analysis to wash contaminants off a component or
assembly.
Particle load: Solid particles from the production process and surrounding area on the control
surface of an object; if the object is in liquid form, the particle load comprises the
particles contained in the liquid.
Control surface: Part or full surface of an object subject to technical cleanliness requirements.
VDA: Verband der Automobilindustrie (German Association of the Automotive Industry).
VDA 19: Regulation for inspection of technical cleanliness - particulate contamination of
functionally-relevant automotive components – Verband der Automobilindustrie
Cleanliness level: Specified or measured value for a cleanliness feature, e.g. particle count.
Extraction process: Procedure for the transfer of the full particle load (where possible) from the control
surface to the test fluid for analysis.
6. Responsibilities
The supplier is responsible for ensuring that components and packaging materials meet the required levels of
cleanliness. The supplier must take all necessary measures to ensure the cleanliness of the components up to
delivery to the customers plant. Corresponding documentation must be provided with information on the
cleanliness of the components/assemblies and their packaging at all stages of the process. The supplier must
install the necessary processes and procedures to create this documentation.
7. Cleanliness requirements entered on drawing
The specified cleanliness class (Table 3, chapter 9.2.2) is included on the drawing above the title block (see
Figure 1). The control area relevant for the cleanliness analysis is marked by a wide dashed line or semicolon
line (according to DIN ISO 128-20) and supplemented by the specification of the corresponding area size in
square centimeters and the TV version (see example Figure 1).
Without a surface specification on the drawing, a cleanliness class according to TV-02023 cannot be
evaluated. If the entire component is subject to a cleanliness specification, it is sufficient to note this on the
drawing (see example Figure 2).
If the product is a BMW product, the "Additional requirements to TV-02023" (starting from version 14) apply
and the cleanliness specification must be extended by a requirement class.
Example:
Cleanliness requirement according to TV-02023 Version X, SK II
entire component surface = 264 cm²
Requirement class: AKL-A (only necessary for BMW products)
Figure 1: Example – Drawing entry showing cleanliness requirements and relevant control surface
Figure 2: Example 2 – drawing entry for cleanliness requirement (AKL only necessary for BMW products)
8. Test planning – Timing of test – Reaction plan – Root cause analysis
8.1. Pre-production phase

Parts which drawings include cleanliness requirements must also be delivered and packed with a cleanliness
certificate in accordance with this specification in the pre-production phase (trial phase). Should this not be
possible due to a lack of time, equipment or other reasons, the supplier must reach agreement on this with
the relevant contact from the development department and the department for technical cleanliness at
ThyssenKrupp Presta Steering.
8.2. Sampling for production/Initial sampling

The cleanliness requirement is to be considered like any other component specification. Corresponding
verification must be provided and documented in the initial sample documents. This applies to both the
components and the associated series packaging.
If the series packaging is not yet defined/available at the time of the initial sample inspection, the supplier
must enclose a concept with the initial sample documents which shows how compliance with the cleanliness
requirements is to be ensured for series deliveries. As soon as the series packaging is available, further
verification must be provided that the series packaging including transport has no negative influence on the
cleanliness of the components. The tested components must be transported in the series packaging or
passed through a transport simulation.
For shipping clean packaging has to be used. The supplier is responsible for using clean packaging. Until it is
proven that the cleanliness specification including transport influence is met, the sampling result cannot be
"green". In these cases, the result must be at maximum "Free with conditions" until verification.
8.3. Initial sampling
With regard to cleanliness, the initial sample documents must contain at least the following information:
- detailed result of the qualification test/decay test (including the individual analysis reports)
- Applied cleanliness test procedure including work instructions with the routine parameters
- Amount of tested parts
- Result of the cleanliness test of at least three components/inspection lots
- Pre-series confirmation (see chapter 15.1)
- Verification of the cleanliness status of the serial packaging (at least quick test according to chapter
13.1)
- verification of the cleanliness condition of the components after transport (or transport simulation) in
the series packaging of at least three components/ inspection lots
8.4. Inspection by external laboratories

If the cleanliness specification is not connected to an <H> or <K> characteristic, the technical cleanliness
inspection can be carried out by an external laboratory. In this case, the verification shall be carried out by the
external laboratory as described in this TV. If tests are to be carried out by an external laboratory, the external
laboratory must be checked and accepted by the technical cleanliness department of ThyssenKrupp Presta
Steering at the start of the project, but at the latest before sampling. If the approved external service provider
is changed in an ongoing project, approval must be obtained from ThyssenKrupp Presta Steering.
For components that have an <H> or <K> characteristic on the cleanliness specification, it is imperative that
the supplier has its own in-house laboratory for technical cleanliness, as well as suitable testing equipment
and well-trained testing personnel. Outsourcing the testing to an external laboratory is not suitable for these
characteristics due to the required reaction time.
8.5. Series delivery to the customer

The supplier shall ensure that the cleanliness specification is met and that the currently valid TV-02023 is
complied with. The required executions must be documented by means of appropriate work instructions.
Measurement and test results are to be stored according the rules relevant to quality assurance and presented
to ThyssenKrupp Presta Steering on request.
If the supplier detects deviations from the agreed cleanliness specifications of the parts to be delivered or the
packaging, appropriate reworking is permitted. In this case it must be ensured that the reworking does not
negatively affect the function of the component/assembly. The supplier must ensure that packaging
corresponding to the cleanliness of the components is used and verification must be provided that the
packaging has no negative influence on the cleanliness of the components during transport.
The supplier must inspect the cleanliness of his components and packaging at regular intervals and these
results must be presented on request. In the case of components (EPS electric motors, cast housings for EPS,
sensors incl. components and control units incl. components) for which the CD-00123 Supplier Logistics
specifications require a packaging test (e.g. ISTA 3E) at a certified testing institute, the cleanliness of the
components and packaging must be verified according to this test.
The number of components/inspection lots to be tested should be appropriate. If no other arrangement has
been agreed with the respective customer, as a minimum requirement for in-house production, the rules
defined in the following Table 1 must be followed. Results of the tests accompanying series production may
be used as re-qualification results.
8.6. Incoming inspection of supplier parts
Unless otherwise agreed with the customer, critical components (e.g. ECU, sensor units, etc.) shall be tested
by an incoming inspection (WEP) with skip lot procedure.
Table 1: Regulation of the test frequency for technical cleanliness
8.7. Reaction plan for limit value exceedance

In accordance with VDA 19, TecSa limit values represent intervention limits and not tolerance limits. Exceeding
them does not necessarily lead to an error, but the risk increases. If a limit value is exceeded during a test, a
re-examination is permissible. In the following, a distinction is made between a single and a triple inspection.
The classification of characteristics defines when which inspection has to be applied.
8.7.1. Single inspection

If the limit value of a component/assembly (A-sample) is exceeded without a characteristics classification or
with <NA>/<NB> characteristics on the cleanliness specification, a single inspection must be carried out. This
means that if a limit violation is detected, a further component/inspection lot or assembly from the same
production period/production batch is inspected (B-sample). If this re-examination is within the limit values,
the test may be evaluated as OK. Both results must be documented, the B-sample may not replace the
A-sample. If the B-sample also shows that the limit values have been exceeded, the affected batch must be
blocked and a root cause analysis must be initiated. At the same time, a deviation permit has to be created
and a risk assessment with involvement of development has to be entered.
8.7.2. Triple inspection

If the limit value of a component/assembly (A-sample) with the characteristic classification <H> or <K> on the
cleanliness specification is exceeded, a triple inspection must be carried out. This means that if a limit
violation is detected, three further components/inspection lots or assemblies from the same production
period/production batch are inspected (B/C/D-sample). If all three verifications are within the limits, the test
may be evaluated as OK. All results must be documented, the B/C/D-samples must not replace the A-sample.
If a further limit violation is detected in the triple check, the affected batch has to be blocked and a root cause
analysis has to be initiated. At the same time, a deviation permit has to be created and a risk assessment on
with involvement of development has to be entered. In addition, an increased inspection cycle must be
adhered to in the next 6 weeks, in which at least one component/inspection lot must be tested per week. If
more than two limit value violations are detected during this period, the increased test cycle is extended by
further 6 weeks.
8.7.3. Reaction plan in the event of limit values being exceeded in a re-examination
If a limit value is also exceeded in a re-examination, the following reactions must be initiated immediately:
- Limitation of the scope of parts affected
- Clarification as to whether the affected part scope is still within the suppliers control
- Initiation of the blocking process of the affected batch/production lot
- Initiation of the problem solving process
- Active self-disclosure to the responsible SQM and creation of a special deviation
- In-depth root cause analysis including EDX analysis
- Application of immediate measures
- Conduct expert discussion with ThyssenKrupp Presta Steering
- Carrying out a risk assessment with ThyssenKrupp Presta Steering
- Application of long-term measures
8.7.4. Root cause analysis/Further analysis

If the limit value is exceeded in the re-examination, a root cause analysis must be carried out. In the course of
the root cause analysis, a further analysis should be carried out on the particles responsible for exceeding the
limit value. This should include the determination of:
- Information on the particle material
- Clarification of the possible origin (components, assembly line, etc.) of the particle(s)
- Particle formation mechanism (scratching, etc.)
- Damage potential of the particles (hardness, conductivity, abrasiveness, etc.)
The above information can be determined by SEM/EDX analysis. A LIBS or Raman analysis can also provide
the needed information. The results of the further analysis must be taken into account in the risk assessment.
Figure 3: Flow chart for serial testing and limit value exceedance
9. Preparations for cleanliness testing
9.1. Testing method

The selection of the test method for assessing technical cleanliness is primarily based on the
component/assembly and the material, type and quantity of particles to be tested. A procedure according to
VDA 19 specification is to be applied. The E1 "pressure rinsing" procedure is recommended, other procedures
are possible. This is a procedure in which defined components/assemblies are rinsed with a liquid (test liquid)
and the particles picked up by a filter are evaluated under a stereo microscope.
9.2. Definition of cleanliness classes

The following describes the cleanliness classes defined by ThyssenKrupp Presta Steering which apply to
components/assemblies depending on requirements and functionalities. In accordance with the drawing entry
referencing the technical specification (TV-2023 Technical cleanliness requirements for components and
assemblies) and the cleanliness class SK I to SK VI, the maximum permissible particle sizes and particle
concentration per 1000cm² component surface are defined. Definition of the cleanliness classes is based on
particle size classes and particle concentration classes.
It is also possible to use other specifications, these should be discussed with the technical cleanliness
department before the drawing entry. Specifications on the drawing must also be technically testable and
reasonable for the respective application.
9.2.1. Particle size classes

Particle sizes are graded by size classes in accordance with VDA 19
Table 2: Particle size classes (according to VDA 19)
9.2.2. Cleanliness classes SK I to SK VI

The cleanliness classes SK I to SK VI are shown in Table 3 and describe the maximum permissible numbers of
total particles and particles with metallic shine in the respective size classes. Fibers are excluded from the
evaluation and may not be counted in the total particle quantity. Fibers may only be classified as "fiber" and
should be considered separately if required by the specification.
The quantity of particles with metallic shine is a subset of the total number of particles. The prerequisite for
this is the evaluation with an automatic evaluation system (e.g. from Jomesa), which first records the total
number of particles with an image processing system and distinguishes the particles with metallic shine by
using a polarizing light source.
The cleanliness class is to be determined by the development and selected in such a way that the maximum
permissible particle size does not allow any loss of functionality. It should be "as clean as necessary, not as
clean as possible". For example, if particles < 200µm are not relevant, they should not be specified. The
required cleanliness classes for components/assemblies are specified in the respective drawing.
Table 3: cleanliness classes (SK) and max permissible particle counts per 1000cm²
*total max. permissible total particle count per size class (without fibres)
**metallic thereof max. permissible metallic particle count per size class
The scaling of the particle amount to 1000cm² can have the effect, that contrary to what Table 3 suggests no
particle may be found during an actual cleanliness testing of test surfaces <1000cm². This is especially
concerns the cleanliness classes which allow only a single particle per 1000cm² per size class. In these cases
it may be useful to adjust the specification accordingly and use a modification of the cleanliness class.
Example:
Component surface: 500cm² Cleanliness class: SKI specified
1 component tested, 1 metallic particle found in particle class "I"
--> 2 particles per 1000cm² and therefore not compliant to specification
--> in actual testing no particle in size class "I" is allowed to be present
Possible Solution: specify modification of SKI in which 2 particles per 1000cm² are allowed in particle
size class "I"
Figure 4: example for drawing entry of a modified cleanliness class

9.3. Definition of particles and burrs
Particles in the sense of technical cleanliness are all solid, small particles that are not functionally intended.
Loosened burrs or burrs that can be loosened by sampling are treated as particles.
10. Cleanliness testing

Cleanliness testing is carried out in accordance with VDA 19.1 “Inspection of Technical Cleanliness –
Particulate Contamination of Functionally-Relevant Automotive Components”.
The following procedure must be applied to:
- Cleanliness requirements on the component/inspection lot/assembly
- Control surface of the component/assembly to be sampled
- Amount of parts to be tested
- Requirements on materials and equipment used
- Determination of blank value
- Qualification tests (decay behavior)/Validation of testing method
- Component cleanliness testing
- Packaging cleanliness testing
- Documentation of the cleanliness of components and packaging, stating the test results obtained and
using the template documents (see chapter 17)
10.1. Cleanliness requirements on the component/assembly

The cleanliness classes SK I to SK VI or specifications deviating therefrom can be seen in the respective
drawing.
10.2. Control surface and number of the component/assembly to test

The relevant control surface for the component/assembly is indicated in the drawing. The number of
components/assemblies required for an analysis depends on the component surface size. Enough
components must be tested at the same time that a minimum surface of 200cm² is tested, this is then called
a test lot. The criteria for the qualification test (decay behavior, chapter 10.4 to 10.6) must be fulfilled.
10.3. Part removal, part handling and transport of the test samples
Because technical cleanliness is a variable temporary characteristic that can be changed by external
influences, the process must be described in the work instruction. Influences such as the handling of parts
during sampling, transport to the test laboratory and storage of the test item until testing must be included in
the work instructions. The cleanliness condition of a test component must not be changed after sampling on
the way to the cleanliness test in the laboratory.
When removing the test specimens, it must be ensured that sufficient components are taken so that, if
necessary, a re-examination can be carried out on the same batch and/or daily production. If it is to be
expected that comparable parts are no longer available, sufficient reserve samples must be taken for a
re-examination.
10.4. Requirements on materials and equipment used

All materials and equipment must meet the requirements stipulated in VDA 19.
10.4.1. Test fluid
The test fluid must be suitable to remove the particles from the components/assemblies being tested for
subsequent extraction via the analysis filter. It must be compatible with the filter material and the parts to be
tested and must not attack them. The test fluid must display adequate minimum purity in accordance with the
cleanliness requirements for the part to be tested. The purity of the test fluid must comply with class 12/9 of
ISO 4406 as a minimum. It may not contain particles > 50µm.
10.4.2. Testing facility

The cleanliness of the test environment must be adapted to the cleanliness level required by the
components/assemblies. This includes the environment as well as all devices, vessels, analysis filters and test
equipment (e.g. spraying equipment, ultrasonic devices, test benches, etc.). The analysis chamber and all
parts used in the analysis must be cleaned with the test liquid until a permissible blank value is reached.
10.4.3. Test equipment

The test equipment used to extract the particles must be state-of-the-art and must monitor/display at least the
following parameters:
- Volume flow (L/min)
- Pressure (mBar)
- Volume display
The exception is the ultrasound procedure, where the frequency and time must be documented.
It must be ensured that no particles are lost during the extraction process.
The following manufacturers of suitable test equipment are recommended for use in cleanliness analysis:
- Image analysis microscopes:
o Jomesa Messsysteme GmbH
- Extraction equipment:
o Hydac GmbH
o Gläser GmbH (for small components e.g. screws)
Deviations from the recommendation of the equipment to be used can be made in consultation with the
ThyssenKrupp Presta Steering department. Flatbed scanners are not permitted as test equipment.
10.4.4. Analysis filter/membrane

The selected analysis filter must be compatible with the test fluid and all solvents or chemicals used in the
testing process. The pore size of the analysis filter must be selected so as to ensure retention of the relevant
particles in line with cleanliness specifications. That means the size of the pores of the membrane used must
be 1/10 of the smallest particle size of particle considered.
Example: Relevant particles start from 50μm --> The size of the pores of the membrane to be
used must not exceed 5μm.
Before the analysis membrane can be evaluated under the microscope, it must be dried in a drying oven after
extraction.
10.4.5. Filter occupancy
In order to ensure optimal microscopic analysis, the filter occupancy after extraction must not be too high. If
the maximum permissible filter occupancy is exceeded, the particle load must be re-prepared or the analysis
must be repeated with a new component/inspection lot, in which case the extraction must be carried out using
several filters.
Permissible filter occupancy for foamed membranes: max. 1.5%.
Admissible filter occupancy for sieve mesh filters: max 3 %.
10.4.6. Maintenance and calibration of the test equipment

In order to be able to carry out the most precise and reproducible analysis possible, it is important to maintain
and calibrate the measurement analysis system, test standards and extraction equipment at regular intervals.
Extraction equipment should be maintained and calibrated according to the manufacturer's instructions. The
cycle should be appropriate but should not exceed a period of two years.
10.4.7. Measurement analysis system

The measuring microscope shall be maintained and calibrated by the manufacturer at least once a year.
A test standard (e.g. particle standard from Jomesa) is used for self-checking whether the microscope is
working properly and must be counter-measured by the manufacturer at least every 4 years.
The self-check by means of a test standard should be carried out at least once a week.
All the above-mentioned maintenance, calibrations and self-checks must be documented.
10.5. Determination of blank value

Before each test, the testing equipment must be cleaned and the permissible blank value verified. The blank
value is based on the cleanliness requirements of the relevant test object. The blank value criteria and
examples are shown in Table 4.
It is permissible to test several components of the same part number after performing a blank value, provided
the test is limited to one day. As soon as a test is to be carried out on a component with a different part
number, a new blank value must be carried out before the next test. If the same component is tested over
several days, a blank value must be verified at least once a day (also see flow chart Figure 7).
Table 4: Blank value criteria and examples
Figure 5: Specification for blank value determination
10.6. Qualification tests (decay behavior)/Validation of testing method

The aim of the cleanliness test is to determine the particulate contamination on cleanliness relevant areas of
assemblies and components by means of a suitable extraction procedure. The extraction procedure used
must be documented for each component/assembly by qualification tests with regard to its effectiveness for
particle cleaning in accordance with VDA 19 and this TV. If a process change takes place and this process
change has an influence on the cleanliness condition, the decay investigation must be performed again.
10.6.1. Decay measurements:

The suitability of the selected extraction conditions is determined by repeated sampling of the same
component/assembly. Over these measurements there must be a defined decrease of the particle count.
The measured particle load values are recorded and the decay behavior illustrated in a graphic. (see example
Figure 6) A blank value measurement is carried out before and after the decay measurement. Both blank
values are to be included in the evaluation.
The decay test must be carried out with the same method that is used for the subsequent routine sampling. In
example, if the pressure rinsing method is to be used, the decay test must be carried out with the pressure
rinsing method. It is not permissible to perform the decay test gravimetrically if the cleanliness requirement is
specified granulometrically.
Figure 6: Decay behaviour (example)
Figure 7: Flow chart for qualification analysis
10.6.2. Start parameters for the decay analysis
The settings defined in Table 5 should be used as starting parameters for the decay test. If other test methods
are used, the start parameters defined in VDA 19 Part 1 shall apply.
Table 5: start parameters for the decay investigation
10.6.3. Decay criterion ≤10%

From the results, the routine sampling parameters are derived which are necessary to reach the required
decay behavior (e.g. total amount of liquid required). The measured value of the individual samples is divided
by the sum of all measured values and the result is multiplied by 100.
The decay criterion is fulfilled if the result is less than or equal to 10 percent within the six samples. It must be
ensured that the less than or equal to 10 percent criterion is not only achieved on the total particle quantity,
but also in the individual particle size classes. The criteria described in chapter 10.6.4 Impermissible decay
tests must also be applied. Only if all requirements are met, the qualification test is considered passed.
For the calculation of the routine sampling procedure it must be ensured that the total volume is calculated in
such a way that the sample in which all conditions are fulfilled is included in the total volume. For example, if
all criteria are met in the fourth sampling, the volume used in the decay test must be multiplied by four. The
resulting volume is the total volume for the routine test.
Example for calculating decay analysis:
10.6.4. Impermissible decay tests
It is unacceptable that, after reaching the ≤10 % criterion, the values for the total quantity of all particles as
well as for the individual particle size classes rise above 10% again (see example 1 given below). If this is the
case, the decay test is considered not to have been passed and must be repeated with changed parameters.
After reaching the ≤10 % criterion, it is furthermore not acceptable that particles larger than the maximum
permissible particle size according to the cleanliness specification are detected in the subsequent extraction
steps (see example 2 given below).
Example 1:
Table 6: Example for the calculation of the decay criteria; the decay criteria is not fulfilled because the values exceed 10% in
some of the particle classes
As can be seen in Table 6 above, the ≤10 % criterion is met for sampling 4 and 5, both in the total amount
and in the individual particle size classes. However, as the value in the sixth sampling rises above 10% again
in size classes F and G, the decay test must be rated "failed" and repeated with modified parameters.
Example 2: SK II specified
Table 7: example of non-conform decay test; non-conforming particles found after reaching the 10% criteria (SK II specified)
As can be seen in Table 7 above, the ≤10% criterion is achieved both in the total amount and in the individual
particle size classes at sample 4. In sample 5 a particle larger than allowed by the specification is detected.
This means that the decay test must be evaluated as not passed. The decay test must be repeated and the
parameters changed so that all relevant particles are safely cleaned off.
11. Component/assembly cleanliness testing

The extraction procedure to be used for the cleanliness inspection is "E1 pressure rinsing" according to
VDA 19. If this procedure cannot be used for component-specific, technical or other reasons, another suitable
extraction procedure according to VDA 19 must be selected in consultation with the responsible department of
ThyssenKrupp Presta Steering.
The particle load collected on the analysis filter is evaluated under the reflected light stereo microscope. To
check whether the required cleanliness class is met, particle counts of the respective size classes are carried
out according to Table 2. For this purpose, the total particle count is determined and then the partial quantity
of particles with metallic shine is determined. From the values obtained, the particle concentration per
1000cm² is calculated and the numbers are rounded to two decimal places. It is not allowed to round results
smaller than one down to zero.
Prerequisite: Automatic counting methods are used for particle counting. (e.g. microscope with particle
evaluation system, Jomesa) The microscope must automatically distinguish between metallically shiny,
non-metallic shiny particles and fibers. This corresponds to the current state of the art. This does not eliminate
the need for a subsequent examination of the relevant particles by qualified test personnel.
12. Archiving the filter membranes

The membranes used with the particles detached from the cleanliness analysis must be archived for at least
one year using suitable means. It must be ensured that a subsequent measurement or if necessary a further
analysis of the particles can take place.
13. Packaging cleanliness testing
The packaging is to be regarded as an essential part of the component/assembly. The same cleanliness
requirements apply to it. In principle, its verification has to be carried out using the same procedures.
However, in order to limit effort, time and costs, two test methods for quick and easy verification of packaging
cleanliness are described below. The extraction methods are binding, but in most cases ThyssenKrupp Presta
Steering accepts the quick test method. For each component cleanliness test, a corresponding packaging
cleanliness quick test must be carried out and documented with the documentation for the component.
Accordingly, samples of the component and packaging are taken in the ready-to-ship condition. The supplier
must ensure through proper packaging that the parts to be delivered are delivered in the cleanliness condition
defined in "TV-2023 Technical cleanliness requirements for components and assemblies".
13.1. Quick cleanliness testing of direct packaging

Direct packaging is the packaging directly enclosing the component/assembly. A quick cleanliness test
(adhesive tape test or particle stamp) has to be carried out on direct packaging each time a cleanliness test is
carried out on the component/assembly.
13.2. Adhesive tape test

An approximately 10cm long colorless, transparent adhesive tape is attached to the test surface and pressed
down firmly. The tape is then removed and attached to a suitable surface (e.g. a white sheet of paper) for
examination. Particle sizes are measured using an 8x measuring magnifier with 100 µm graduations. The test
is passed if no particles are detected which are bigger than the maximum permissible particle size for the
component to be delivered. The adhesive tape test must be carried out in at least three positions and the
results must be documented.
13.3. Particle stamps

Another possibility would be to use particle stamps to check the cleanliness of the packaging. The largest
possible diameter of the particle stamp that can still be evaluated under the microscope should be used here
(JOMESA: max 47mm). The particle stamp test should be carried out in at least three positions and the results
documented.
14. Inspection of the environmental cleanliness

For components that are subject to a cleanliness specification, it is important to check the environmental
cleanliness at regular intervals in order to identify sources of contamination and prevent cross-contamination.
Ambient cleanliness is tested by means of particle traps (see Figure 8). For this purpose, different measuring
points are to be defined, and these points have to be fixed in a work instruction. The test time is at least one
week. The particle trap is then evaluated under the microscope and the results are given as a so-called
sedimentation number or Illig value.
The limit values depend on the component specification and should not exceed the following limit values:
- Requirement TV-02023-SK 1 Illig value not greater than 50 [1/1000cm²h]
Figure 8: Schematic design of a particle trap
15. Confirmation of technical cleanliness over product lifetime
15.1. Pre-series confirmation

The pre-series and series confirmation shall be demonstrated for components/inspection lots and assemblies
for which the cleanliness requirement according to this TV has been assessed with the characteristics
<K> critical characteristic or <H> main characteristic and is marked accordingly on the drawing.
To prove the pre-series confirmation, 25 components/inspection lots are taken from the machine or process
(e.g. assembly process) one after the other and the prescribed test of technical cleanliness is carried out. The
pre-series confirmation is considered passed if the 25 tests are within the required limits and the
re-examination rate does not exceed 10%.
The ThyssenKrupp Presta Steering template FS-12319 shall be used to document the results of the pre-series
confirmation.
Figure 9: Flow chart of the pre series confirmation
15.2. Series confirmation
The pre-series and series confirmation shall be demonstrated for components/inspection lots and assemblies
for which the cleanliness requirement according to this TV has been assessed with the characteristics
<K> critical characteristic or <H> main characteristic and is marked accordingly on the drawing.
The series confirmation is carried out in the same way as the pre-series confirmation on the basis of at least
25 components/inspection lots (including permissible re-examinations, see Figure 10). However, the
component sampling for the samples is carried out with a time delay (2-3 components/inspection lots per
month for the first 12 months). The time intervals shall be selected in such a way, that all recognizable time-
dependent process influences are recorded.
The determination of the technical component cleanliness is carried out promptly after taking the samples of
the components/inspection lots, so that any existing, time-dependent influences in connection with the
performance of the analysis are also included and can be detected if necessary. Under no condition may the
components/inspection lots be collected and then analyzed simultaneously. The proof of pre-series
confirmation must be demonstrated within the scope of the initial sampling and documented and provided
with the initial sample documents. The procedure described above is the rule.
The ThyssenKrupp Presta Steering template FS-12319 shall be used to document the results of the series
confirmation.
Figure 10: Flow chart of the series confirmation
16. Documentation of component/assembly and packaging cleanliness
The assessment of each analysis is documented in the form of a report by the responsible laboratory.
The report shall contain at least:
1.) The ThyssenKrupp Presta Steering part number and the name of the component or assembly
2.) The tested area (control area) (e.g. whole component)
3.) The surface area of the component in cm²
4.) Date of extraction and date of analysis
5.) The extraction procedure used, the rinsing medium and rinsing volume
6.) number of the working instruction
7.) the filter material used and the pore size of the filter
8.) Microscopic resolution in µm/Pxl (micrometer per pixel)
9.) Filter occupancy in %
10.) Name of the examiner
11.) The number of tested components or component groups
12.) The required cleanliness class
13.) Length and width of the largest metallic and non-metallic particle
14.) Picture documentation of the two largest metallic particles, the two largest non-metallic
particles, the longest fiber and an overview of the membrane filter
Results and evaluation

15.) Result of the blank value
16.) The numbers of total particles and particles with metallic shine per 1000cm² surface area
with the corresponding particle concentration class as well as the total numbers of particles
on the filter
17.) The respectively largest determined particles of metallic and non-metallic kind in µm.
18.) A concluding statement whether the determined values are within the required cleanliness
class of the respective particle size classes.
19.) Result of the quick packaging test
The reports must be submitted to ThyssenKrupp Presta Steering on request. The usual periods for quality
documents shall apply for the storage of the documents. The membranes used with the particles of the
cleanliness analysis must be archived for at least one year using suitable means if further analysis might be
necessary. If a limit value violation is detected a reaction as described in chapter 8.7 has to follow.
17. Related documents
- VDA 19
- Template for cleanliness analysis results (FS-11953)
- Template for work instruction for cleanliness testing (FS-11954)
- Template document for pre- and series confirmation (FS-12319)
- Attachment of TV-02023-EN – Additional requirements for BMW products concerning technical
cleanliness

TV-02023-EN - V15-Technical Cleanliness Requirements - 2023-03-06

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TV-02023-EN - V15-Technical Cleanliness Requirements - 2023-03-06

Uploaded by

Copyright:

Available Formats

Technical Specification TV – 02023-EN

2.1. Functional responsibility, contacts

English version removed and transferred to a separate document

8.4 Added: testing by external laboratories

8.7.3 Added: reaction plan for limit violations in a verification

8. Test planning – Timing of test – Reaction plan – Root cause analysis

8.1. Pre-production phase

8.2. Sampling for production/Initial sampling

8.4. Inspection by external laboratories

8.5. Series delivery to the customer

Table 1: Regulation of the test frequency for technical cleanliness

8.7. Reaction plan for limit value exceedance

8.7.1. Single inspection

8.7.2. Triple inspection

8.7.4. Root cause analysis/Further analysis

9.1. Testing method

9.2. Definition of cleanliness classes

9.2.1. Particle size classes

Table 2: Particle size classes (according to VDA 19)

9.2.2. Cleanliness classes SK I to SK VI

Figure 4: example for drawing entry of a modified cleanliness class

10. Cleanliness testing

10.1. Cleanliness requirements on the component/assembly

10.2. Control surface and number of the component/assembly to test

10.4. Requirements on materials and equipment used

10.4.2. Testing facility

10.4.3. Test equipment

10.4.4. Analysis filter/membrane

10.4.6. Maintenance and calibration of the test equipment

10.4.7. Measurement analysis system

10.5. Determination of blank value

10.6. Qualification tests (decay behavior)/Validation of testing method

10.6.1. Decay measurements:

Figure 7: Flow chart for qualification analysis

Table 5: start parameters for the decay investigation

10.6.3. Decay criterion ≤10%

11. Component/assembly cleanliness testing

12. Archiving the filter membranes

13.1. Quick cleanliness testing of direct packaging

13.2. Adhesive tape test

13.3. Particle stamps

14. Inspection of the environmental cleanliness

15. Confirmation of technical cleanliness over product lifetime

15.1. Pre-series confirmation

Results and evaluation

You might also like