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In our previous article, “Understanding AEC-Q200 Testing for Automotive Electronics,” we explored how AEC-Q200 testing safeguards the quality and safety of automotive electronic components, detailing its key test items and considerations. This raises a critical question: If a magnetic component supplier holds IATF 16949 certification and its products pass AEC-Q200 testing, does that automatically make those products “automotive-grade”?
1. Key Criteria for Defining Automotive-Grade Products
In reality, automotive-grade products require more than just a management system certification or an AEC-Q200 test report. In the automotive industry, the focus is on defect prevention and reducing quality variability (to ensure stability and consistency) throughout the product quality control process. Thus, beyond management systems and testing standards, manufacturing process control is equally crucial. Here are the key aspects to consider:
1.1 Automotive Quality Management System Certifications
As the global automotive market expands and competition intensifies, automakers strive to improve quality, cut costs, and boost competitiveness. In response, Germany’s Verband der Automobilindustrie (VDA) and the International Automotive Task Force (IATF) developed their respective standards—both emphasizing a process-oriented approach to ensure end-product quality by controlling every production stage.
VDA standards, widely adopted in Europe and beyond (not just Germany), include VDA 6.1 (quality management system audits), VDA 6.3 (process audits), and VDA 6.5 (product audits).
IATF 16949, developed by the IATF, provides a unified global framework for automotive manufacturers and suppliers. Built on ISO 9001, it adds automotive-specific technical requirements, making it the internationally recognized quality standard for the industry.
1.2 Meeting AEC-Q200 Standards
Automotive electronic components must pass AEC-Q200 testing to verify reliability under harsh conditions, including high-temperature aging, temperature cycling, vibration, and shock tests. However, some products claiming AEC-Q200 compliance may only meet a few test items.
The latest AEC-Q200 Rev E standard includes over ten test items for magnetic components (inductors/transformers) in Table 5. If a manufacturer’s testing does not cover all required items for inductors, the products may fail in complex in-vehicle environments, posing risks in real-world use.
1.3 Design and Process Control for Automotive-Grade Quality
Beyond AEC-Q200 reliability testing, automotive-grade products must meet other specific standards. During process design, reliability and stability are prioritized: key processes require a CPK of at least 1.67, and design lifespans typically exceed 15 years, with a zero-defect target.
In contrast, industrial-grade products have lower reliability standards and allow for some failure rates. Even if some industrial-grade products pass AEC-Q200 tests, they cannot replace automotive-grade products, which require strict design and process control per automotive quality management systems.
1.4 Consistency Between Test Samples and Mass-Produced Units
In product audits, some companies provide AEC-Q200 reports, but poor manufacturing control may mean mass-produced units differ from tested samples. Others test only specific models but claim all meet AEC-Q200. Both scenarios create quality risks.
2. Requirements for Developing and Controlling Automotive-Grade Products
The automotive industry’s strict quality demands impose rigorous requirements on suppliers, covering quality management systems, process control, raw materials, manufacturing, and reliability. Early planning, manufacturing process control, and in-process monitoring are particularly critical.
2.1 Product Development via APQP
Advanced Product Quality Planning (APQP) is one of IATF 16949’s core tools and a key part of quality management systems. It is a structured method to define steps ensuring products meet customer satisfaction, with the goal of guaranteeing quality and enhancing reliability. Automotive product development must strictly follow the APQP process.
Key APQP Stages:
◾ Plan and Define
◾ Product Design and Development
◾ Process Design and Development
◾ Product and Process Validation
◾ Feedback, Assessment, and Corrective Action
Each stage builds the foundation for the next, ensuring product quality, performance, and efficient, stable manufacturing. This systematic approach has made APQP widely adopted in the automotive industry.
2.2 Process Quality Standards
Automotive electronic components face stringent process quality standards, including raw material selection, manufacturing control, packaging, reliability testing, electrical performance checks, visual inspections, quality certifications, environmental compliance, process monitoring, and statistical control.
Manufacturing process control and in-process monitoring are critical: automotive-grade products require production on strictly defined lines, with minimal deviations under stable process capability and measurement equipment conditions. Each batch’s production process must be inspected to enable proactive defect detection.
For process monitoring, Statistical Process Control (SPC) is used to track and analyze key production parameters, enabling timely resolution of potential quality issues. These high standards ensure components operate reliably in complex, harsh in-vehicle environments over extended periods.
3. Standard Documentation for Automotive-Grade Products
3.1 PPAP
The Production Part Approval Process (PPAP) is a standard to ensure automotive component quality. It confirms that suppliers understand customer engineering requirements and can consistently meet them in mass production.
PPAP aims to guarantee quality during component design and production. All parts in the automotive supply chain require detailed data and documentation to support customer production approval and risk assessments.
PPAP has five submission levels:
◾ Level 1: Part Submission Warrant (PSW) only.
◾ Level 2: PSW with product samples and limited supporting data.
◾ Level 3: PSW with samples and complete supporting data (most comprehensive).
◾ Level 4: PSW and other customer-defined requirements.
◾ Level 5: PSW with samples and complete data, reviewed at the supplier’s facility.
CODACA provides PPAP Level 3 documentation (or meets other customer needs), including:
◾ Part Submission Warrant (PSW)
◾ Datasheet Approval
◾ Engineering Change Documents
◾ Design-FMEA (DFMEA)
◾ Process-FMEA (PFMEA)
◾ Control Plan
◾ Measurement System Analysis (MSA)
◾ Process Flow Chart
◾ AEC-Q200 Reliability Test Report
◾ Material and Performance Test Results
◾ Initial Process Studies
◾ Sample Product
◾ REACH / RoHS Documentation
3.2 IMDS/CAMDS (Raw Material Composition)
To restrict harmful substances, the automotive industry uses systems to manage material composition—with IMDS playing a key role.
The International Material Data System (IMDS) is used by automakers and ~120,000 suppliers worldwide. It stores data on all materials and their chemical compositions, enabling collection, updates, analysis, and archiving of materials used in automotive manufacturing. It guides OEMs and suppliers in complying with global regulations. CAMDS is China’s equivalent of IMDS.
IMDS enhances product quality, safety, and environmental performance while driving industry innovation and competitiveness. CODACA provides IMDS/CAMDS documentation as required.
3.3 Environmental Compliance
To protect the environment and ensure sustainability, automotive electronics must meet regulations like RoHS, REACH, and Halogen-Free standards. As a leading magnetic component manufacturer, CODACA recognizes environmental importance—all product designs comply with international environmental standards.
4. Additional Requirements
Growing demand for automotive electronics reflects a customer-centric trend. Beyond the above standards, some customers request product portfolios, roadmaps, etc., to assess a company’s overall strength in automotive electronics.
With 24 years of inductor development expertise, CODACA offers low-loss, high-reliability automotive-grade inductor solutions. We strictly manage quality per the IATF 16949 system, with German customers applying VDA 6.3 standards.
CODACA selects raw material suppliers carefully, follows APQP in development, and uses an advanced Manufacturing Execution System (MES) to enhance production control, material management, and quality traceability. Digital management improves efficiency and enables full-process quality tracking. Our CNAS-accredited laboratory conducts comprehensive in-house AEC-Q200 testing.
With 20+ years of experience and continuous innovation, CODACA independently develops inductor core materials and customizes products. Our experienced R&D team quickly delivers tailored inductors to meet the automotive industry’s needs for diversity, flexibility, and innovation.