MAN Nutzfahrzeuge AG WORKS STANDARD March 2007
Procedure for compliance with regulations and safety
requirements
for MAN products M 3010-2
Parts with documentable characteristics
Dimensions in mm
This English version is a translation. In case of doubt or conflict the valid German-language original will govern.
Contents
1 Scope and purpose
2 General principles
3 Duty of documentation and archiving
4 Documentable parts and characteristics, identification
5 Part types that can have safety-relevant characteristics and/or requirements,
whose noncompliance can have a critical impact on the road and/or
functional safety of the products or vehicles
6 Example of critical documentable characteristics
7 Appendix A, Notes on implementation in Production and Service
1 Scope and purpose
This standard governs all truck and bus business units / sites, all central departments of MAN and all
development suppliers of MAN.
This standard governs the verification of compliance with the regulations and safety provisions in the
development, production and service of products of MAN-Nutzfahrzeuge Aktiengesellschaft (MAN).
This standard governs both new and modified inhouse and purchased parts and/or our parts, parts procured
externally and industry-wide standardised parts (definitions according to DIN 199-2) that are used as individual
parts and groupings/assemblies in end products from MAN or as spare parts in Service. (Hereinafter called "parts".)
Section 5 of this standard contains a list of the part types for which the duty of documentation according
to Section 3 applies as verification of compliance with individual safety-relevant characteristics
(e.g. material treatment or crack detection).
The provisions in Sections 2 and 4 must be complied with for parts procured externally and components
manufactured by third parties.
2 General principles
- The manufacturer must basically be in a position to demonstrate compliance with all applicable
regulations and safety requirements for the development and production of parts and products.
(For an overview see Figures 1 to 3 in M 3010-1)
- To this end, the manufacturer/service of parts or products must be basically able to demonstrate, in
respect of his quality assurance system and his tests and inspections, that they have been manufactured
according to the valid item definition or specification and that they also satisfy these requirements.
(see Volume 1 of the VDA Publications Series Quality Assurance in the Automotive Industry,
Verification Management)
- In addition, for parts with a particular safety relevance, and for individual particularly important
characteristics, MAN Design may, for verification to authorities and in the event of a claim, explicitly
require the duty of documentation according to Section 3, by the identification according to Section 4
in the MAN drawings or in the purchased part drawings.
- The documentable characteristics must be clearly measurable and/or verifiable at all times.
- Characteristics to be tested, for which the normal verification management and archiving period is
sufficient, must not be defined as D characteristics but preferably as 100% inspection characteristics.
Continued on Page 2 to 6
Prepared by: Waber, TDN Release TDN: Replaces: 1998-11 Material group no.:
2007-05; englisch
MAN Nutzfahrzeuge Aktiengesellschaft, Munich works – Dept. Normung (TDN) x All rights reserved according to ISO 16016.
Distribution and use of the contents are not allowed without written permission from MAN Nutzfahrzeuge Aktiengesellschaft.
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M 3010-2 : 2007-03
- The parts themselves must be permanently marked in accordance with MAN 312 and MAN 315 for
traceability/return and identification in the event of damage or loss.
- In the case of purchased parts, parts manufactured by others and inhouse parts that are processed
externally according to Q 013, the manufacturer must be advised of the required duty of documentation as
soon as possible, i.e. promptly but not later than with the order.
- The scope and execution of the duty of documentation must be agreed by the manufacturer with the
Quality Assurance department of MAN.
- MAN must be notified of any change to the parts, as well as to the production and testing procedures so
that they can clear such changes.
3 Duty of documentation, special duty of archiving
Duty of documentation is the duty of Development, Production, Assembly and Service of MAN and/or of the
manufacturers/suppliers to keep, for certain safety-relevant parts and/or characteristics identified in Section 4,
detailed documentation of the quality requirements (product specification, test instructions) and of the quality
records (test results, test instructions and other quality assurance measures), which prove without gaps that
Production/Assembly/Service have complied with the values and/or requirements laid down in each particular
instance over the entire manufacturing/repair period.
The documentable characteristics must be clearly measurable and/or verifiable at all times.
This documentation, e.g. FMEAs, risk assessments, reports of experiments, test reports, production and
assembly drawings, repair procedures, quality records and other documents, must, in conformity with Volume 1 of
the VDA Publications Series – Quality Assurance in the Automotive Industry, Quality Evidence - be managed in
an appropriate form over the entire period of use, and be held ready for presentation to the customer or to the
authorities, and must be marked in a manner that is readily identifiable, preferably with a "D".
These documents with D characteristics are subject to the special duty of archiving, with an archiving period of
at least 15 years from the end of the period of use of the documents.
4 Documentable parts and characteristics, identification
For safety parts (M 3010-1, Section 3.1) from the part types according to Section 5 of this standard, the designer
must decide, on the basis of the risk assessment or FMEA and if necessary in consultation with Product
Preparation/Quality Assurance, whether and for which safety-relevant characteristics (see also Section 6) a duty
of documentation according to Section 3 must be laid down.
This must then be identified in the drawing (including external drawings) as follows:
- Drawings containing documentable characteristics must be identified in the MAN drawing title block
according to MG. 110.01-2 and in drawings for purchased parts by means of a sticker according to
M 3122 with the identifier "D" and the designer's test certificate.
- The documentable characteristics must be identified in the drawing by a bar over (e.g. testing according to )
For externally procured parts, those parts and characteristics which are documentable can be specified by the
manufacturer in consultation with the MAN Design department, and the type of identification in the drawing of
externally procured parts agreed upon.
Parts with documentable characteristics are also given the identifier D in the SADIS master data, screen TE23A,
TK field.
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5 Part types that can have safety-relevant characteristics or requirements, whose noncompliance can
have critical effects on the road and/or functional safety of the products or vehicles.
Not all components made from the part types or item number stems listed in Table 1 need necessarily have
safety-relevant characteristics or requirements. (e.g. all non D-relevant small parts, brackets, lugs, shims etc.)
This also applies to higher or lower ASSY groupings of these part types, which need not contain any critical
documentable characteristics.
In case of doubt therefore, the user should check in field TK in SADIS screens TE20A and TE23A to see whether
a duty of documentation for characteristics has been defined for such components or ASSY groupings.
Table 1, Part types which can have safety-relevant characteristics
Description of the part types Item number stem
ABS system (sensor, pressure control valve, electr. control unit) xx.52452-
Axle guide xx.430xx-
Stub axle xx.36301-
xx.36302-
xx.44201-
Stub axle pin xx.44205-
xx 36305-
Stub axle carrier xx.44202-
Trailer coupling xx.42001-
Automatic linkage adjustor (brake) xx.50610-
Brake shoes xx.50200-
Brake shoes (without pad) xx.50201-
Brake operation xx.510xx-
Brake shield xx.50202-
Brake drum xx.50110-
Brake cylinder, holder xx.50710-
Centre pivot plate (articulated bus) xx.70810-
Cab closure xx.61800-
Spring bracket, rear xx.41307-
Spring bracket, front xx.41301-
Spring bolt xx.41306-
Spring stirrup xx.41312-
Springs, leaf spring, coil spring xx.43406-
Spring trunnion xx.41309-
Rim (wheel) xx.45427-
Main spring leaf xx.43490-
Rear axle, ASSY xx.35001-
Trailing link xx.43220-
Side member, bearer, rear axle radius arm xx.43201-
Trailing arm and transverse control arm, axle control xx.43260-
Bolt xx.46731-
Guide, ASSY xx.43315-
Guide arm xx.43270-
Steering gear xx.46200-
Steering arm, steering knuckle arm, pitman arm xx.46601-
xx.46705-
Steering arm for articulated bus xx.46701-
xx.46720-
Steering arm stand (articulated bus) xx.46730-
Steering wheel xx.46430-
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Drag rod xx.46610-
Steering shaft, steering universal shaft xx.46113-
Drag rod xx.46715-
Drag rod xx.46710-
Steering support xx.46110-
Steering shaft xx.46122-
Pneumatic spring xx.436xx-
Universal joint xx.46105-
xx.46502-
Wheel (rim) xx.45302-
Wheel bolt xx.45501-
Wheel hub xx.35701-
xx.36501-
xx.44301-
Fifth wheel xx.42710-
Rear cross member xx.420xx-
Rocker (bus) xx.43000-
Carrier block xx.43630-
Door closing system (bus passenger door) xx.74910-
Front axle, ASSY xx.36000-
xx.44000-
Front axle beam xx.44101-
6. Examples of critical documentable characteristics and requirements
Given the significant cost of gapless documentation and especially its 15 year archiving after the end of the
period of use, the duty of documentation may only be defined very restrictively and only for a small number of
extremely critical (FMEA, ERZ) characteristics of really highly-stressed, extremely safety-relevant components
in Table 1 (e.g. in steering, suspension, brake system and axles).
This is why it should always be initially considered whether either the standard 100 % test identifier
with normal archiving period is adequate for these individual critical safety-relevant characteristics, or
whether the proven control of the process at the time of manufacture is adequate instead of
testing/inspecting the characteristic!
Only the truly critical characteristics and/or requirements need then be identified as documentable
characteristics according to Section 4.
Example of documentable characteristics in MN drawings are:
characteristics which involve a product risk factor P > 8 (in regard to strength) for the component when
the development risk number ERZ is determined
characteristics for which an assessment number ≥ 9 was determined or calculated in the FMEA.
material properties and/or material heat treatment (hardening and tempering).
100 % crack inspection
settings or actuation travels
evaluation group/quality requirement for weld seams according to M 3199
road safety-relevant assembly torque settings and their variance
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Standards quoted
DIN 199-2 Terms in drawings and parts lists; parts lists
MAN 312 Item designation; requirements and implementation
MAN 315 Identification of MAN parts procured externally; only for spare parts supply
M 3010-1 Process to comply with regulations and safety provisions for MAN products;
regulations of authorisation authorities and internal design regulations.
M 3122 Tables on drawings, identification of drawings for parts with safety provisions
MG.110-01-2 Labelling field for drawings and drawing changes; information and entries in the
labelling field
VDA 1 VDA Publications Series Quality Assurance in the Automotive Industry, Quality Evidence
Previous versions: M 3010-2 / 08.79, 11.83, 08.84, 11.91, 11,98
Q 006. Version 3
Changes: The following changes were made compared to the 1984-08 edition:
Standard edited
- Additions to lists in section 5 (previously 3)
The following changes were made compared to the 1991-11 edition:
- in section 3, the retention period has been increased to 15 years in accordance
with VDA 1, Quality Management in the Automotive Industry, Quality Evidence.
The following changes have been made since the 1998-11 issue:
- Contents of the withdrawn Q006, Version 3, incorporated
- Scope broadened and service departments included for the first time
- Reference added to Figures 1 to 3 from M 3010-1
- Content added for Assembly and Service interests
- Sections 1, 2, 3 and 4 updated
- Section 5 editorially expanded
- Section 6 added
- Appendix A added
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Appendix A
Notes on implementing the duty of documentation in Production and Service
A.1. General
The quality representative who is responsible for the D part lays down the following requirements:
- the documents necessary for manufacturing and testing
- update service
- the type and place of storage/archiving
As well as test records, test procedures, production and assembly drawings, repair procedures and other
documents must be clearly identified with a "D", managed in a suitable form over the entire period of production
and held ready for presentation to the customer or the authorities.
A.2. Product preparation, workshop support
The production and/or service documents such as test procedures, test reports, production and assembly
drawings, repair procedures and other documents, must specify the production processes in such a way that the
qualitative nature of the parts or service is faultless.
In the case of production processes whose result is determined largely by the operating equipment, it is
permissible for the process capability to be periodically documented instead of testing the characteristics.
A.3. Production, Service
The records must be managed and kept such that they can be used to prove without omissions that the
requirements for the documentable characteristic (or if applicable for the process capability) have been
satisfactorily complied with over the entire period of manufacture (traceability).
The records must contain the following particulars:
- Item number and description
- Characteristic
- Test result
- Date
- Personal identification
- Deviations from the D-characteristic are not permitted. Rejected parts must be quarantined in such a way
that their unauthorised use is impossible.
Quality Department of the Business Unit
The effectiveness of the quality assurance system is monitored by product-internal and product–external process
and system audits.
