Page 1
CommScope, Inc. Confidential
07 Oct 2011
1. GeneralScore(0-3)QuestionWhat is the company size? Annual sales? Totalemployees? Ownership? Percent export sales?qualitycertification?Are currently casted products similar to targetedCommScope products in complexity and intricacy?Is there a documented NPI process? What are typical NPIintervals for products of similar complexity to the targetedCommScope product?How about the language of technical communicaiton andformal documentation?Subtotal000Supplier selfScoreCommscopeScoreDeltaAnswerComments2. Part DesignDoes the supplier have the ability to read Pro/E files andshould be able to provide 3D part database and detaileddrawings in Pro/E format?Does the supplier have the ability to provide the DFMreport? Can provide the suggestion to optimize the partdesign based on the manufacturing feasibility, cost saving,etc?Does the supplier have the ability to modify the casting &machining 3D & 2D regarding the DFM report? Then sendto Commscope for confirmationDoes the supplier have the ability for partsampling/prototypes? in house or outsource?Does the supplier have the ability for testing and evaluationduring design status?Subtotal0003. Casting Tooling 3.1 DesignWhat is the tooling design software?What is the CAM software?How many tool designers? What is the typical tooling duration? Minimum toolingduration to get final die cast parts?What is moldflow software? Can provide the formal moldflowreport?What is the normal die casting tooling life?What is the maximum size & weight of casting part theydesigned for the tool? What is the maximum size & weightof the tool they designed?What is the minimum wall thickness of casting partdesigned?Which type of Alloy of casting part designed?Which steel will be used for inserts and moldbase? Steelheat treatment in house or outside? Can provide the heattreatment certification?What is the design organization and process?How to calculate the filling time, ingate, runner, piston,chamber, die casting machine size,piston stroke andspeed,filling rate etc? please attach the spec if you arefollowing it?Does the supplier have the ability of tool design for vacuumdie casting process?Are there capabilities for two-shot or multi shot, insertcasting,etc.Does the supplier have the process to minimum theporosity? If yes, please explain how to operate?Does the supplier have the ability/process about thethermal management of casting tool during castingproduction? If yes, please explain how to operate?Does the supplier have any coating process on the surfacesof tool to extend the tooling life?If yes, please explain how tooperate?Does the supplier have the ability to build the new tool withthe original moldbase, only replace the new inserts?Does the supplier have any other process which can beimplemented into the casting tool design to achieve a betterquality?If yes, please explain how to operate?Subtotal000CTV-74-005-13
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CommScope, Inc. Confidential
07 Oct 2011
3.2 Facilities/EquipmentWhat is the machines for the tooling fabrication includingthe inspection equipment? Please provide the equipment listwith brandSubtotal0003.3 ProcessCan design the tool in house or with the outside partner?Can design it following the DME standard or the other typeof standard?Would the supplier provide tool designs to Commscope forconfirmation before fabrication?Can the supplier provide the project schedule of toolingfabrication and timely update to Commscope?Does the supplier have the ability for tool trial? And submitthe formal trial report including the improvement solutionsfor trial result?if yes, please attach your trial run formatWhat is the process about the defect improvement after tooltrial?Subtotal0003.4 InspectionDoes suppler have any inspection for the incoming steel,components, etc?Does the supplier have the ability to provide the dimensionreport with CMM, porosity check with X-ray, castingparameters setting for trial conditions record,etc,after eachtrial?What is the other inspection equipments? Please providethe listSubtotal0003.5 ECNSWhat is the design change process? Can provide thedesign record/ tooling modification record?Subtotal0004. Casting 4.1 Facilities/EquipmentDo current casting presses and auxillary equipment supportthe casting of targeted CommScope product Press tonnage,shot size, press brand and model,etc.)?what is the tonnageranges of casting machines? Or does have the miniaturecasting experience?Is there an overhead crane system for handling large dies?What type of the centeral furnace for alloy melting?themelting capacity, brand,type,etcWhat type of the holding furnace for alloy melting?themelting capacity, brand, etcWhat is the transportation equipment for the melting alloyfrom the centeral furance to the holding furnace?What type of ladle?What type of plunger? Material? how cool it? Can providethe general structure?What type of shot sleeve? How cool it?Does the supplier have the mold temperature contollingequipment?if yes,which equipment is used?Does the supplier have the vacuum system?Does the supplier have the spray system automatically?Does the supplier have the robotic arm to take out thecasting parts automatically?Does the supplier have the equipment to monitor the moldtemperature?Does the supplier have the equipment to mix the sprayautomatically?Does the supplier have the equipment or fixtures to cut theingate & runner system, overflow, deburring?Does the supplier have the shot blasting machine? Partwashing equipment? Band saws? polish machine?CTV-74-005-13
Page 3
CommScope, Inc. Confidential
07 Oct 2011
Do current machines support the targeted CommScopeproduct for secondary machining process after casting?Is there available Capacity? if so what kinds else ofmachines can be provided for post process after casting?Does the supplier have the ability for the chromate process?Or any process else for surface treatment?Does the supplier have the ability for the paintingprocess,plating process? Copper plating, silver plating?Nickel Plating?Does the supplier have the equipment for the leakage test?Does the supplier have the impregnator equipment?Does the supplier have the porosity welding equipment?ifyes,which equipment or welding method is used?Does the supplier have the project, CMM, X-ray, spector?Does the supplier have gauges for inspection? Heightgauges,pin gauges,thread gauges,any other checkingfixtures?Does the supplier have the tensile testing equipment?Does the supplier have the spectrometer analysis of thealloy chemical composition?Does the supplier have the surface roughness tester? Doesthey have Micrometer, calipers,depth micrometer?Does the supplier have any other equipments?Subtotal0004.2 ProcessAre there capabilities for two-shot or multi shot, insertcasting,etc.Does the caster have a process monitoring system whichlooks at the casting process for capability? Are variableslike hydraulic and casting pressure being monitored?Does the Casting Shop run 3 shifts/24/7?How is capacity measured (machine hours, labor hours)?Does a monitoring system provide for sequencing andscheduling in the Casting Shop?Are Lean Casting measures evident? Are there measures inplace to reduce set-up time so \"short runs\" are economical?Is there a commitment to housekeeping and workplaceorganization? What is the general look and feel of thecasting Shop?Can support high volume production(10k+units/month)?Are alloys fed from a central system?Does the supplier have a dry, clean warehouse for thestorage of incoming alloy ingots?Does the supplier have an instruction and record for themelting process control? What is the quality control aboutthe ingots melting process in the central melting furnace,transportation to holding furnace, and in holding furnace?Please attach melting process WI if you have?Does the supplier preheat the ladle, tool, alloy beforemelting?What is the steps for alloy melting process? Have anysystem to monitor the melting process?Does the supplier have the refined process to increase themelting quality? If yes, please explain how to operate?What is the process if a casting machine is switched to castanother alloy? How to clean the holding furnace?What is the other aditional process done for the qualitycontrol of melting process?Does the supplier have an instruction for tooling setting ondie casting machine? How to preheat the tool? How approvethe 1st part quality for each lot of production? If have,please explain how to operate?What is the setting for the spray process? The spray type,consistence percentage, how decide the spray area?Distance? temperature? Volume? Etc?If have, pleaseexplain how to operate?CTV-74-005-13
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CommScope, Inc. Confidential
07 Oct 2011
Are the processing parameters used for each casted partdocumented as a \"recipe\" ? How to set these parameters?How to check or monitor all these parameters?Does the supplier have an instruction of casting part checkfor operators?Does the supplier have an instruction for the packing aftercasting from casting machine?Does the supplier keep the first & final casting part withsome notes?Does the supplier have any tooling maintenance after tooldownload from die casting machine?What is the process if casting production paused? Re-start?What is the disposition for the scrap casting parts?What is the tooling scrap process?Does the supplier have the safty rules or process forcasting?Does the supplier have an instruction and record for theprocess of gate cutting,deburring,shot blast,polishing, etc?Does the supplier have an instruction and record forsecondary machining process control after casting?How to control the process change? Do you informCommScope if process is changed? Like change diecomponents? Equipment? Production parameters?Subtotal0004.3 EngineeringDoes the supplier have the basic ability to maintain, inspectthe equipment? Including the casting machine and someother equipment for casting, does have they maintenancerecord?How is the routine maintenance of molds charged? How aremodifications charged? How are spare details for the moldsinspected and controlled?Does the contractract molder have Engineering on staff?Does the contract molder have the ability to maintain ormodify molds in-house? What type of equipment is there intheir toolroom? Brands and type of machine tools.Does the supplier have the ability to design, fabricate thetriming tool in house or with outside partner?Does the supplier have the ability to design, fabricate thegauges in house or with outside partner?Does the supplier have the tooling maintenance instructionand record? Does the supplier have any instruction andrecord for tooling life control?Does the supplier have the spare parts of die in thewarehouse?Does the supplier have the ability to design, fabricate themachining fixtures in house or with outside partner?What is the typical fixture fabrication duration? Minimumfixture fabrication duration to get final machining parts?Does the supplier have ability of secondary machining aftercasting? How does the supplier decide the machining area,machining stock? How decide the machining datum, fixingpoints,machining process?Does the supplier have the ability to design, fabricate themachining production line, assembly line in house or withoutside partner?Does the supplier have ability of plating/painting-powdercoat+chromate+copper plating+silver plating,in house or aplating/painting supplier? Can they have ability for selectiveplating?Subtotal0004.4 MaterialsAre alloy in use the same or similar to alloy used to casttargeted CommScope Product? Are Engineering Grade alloyutilized in current production parts? Where is the alloysource?CTV-74-005-13
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CommScope, Inc. Confidential
07 Oct 2011
Is there a stock of a highly conductive die casting alloy inhouse in the adequate qty to support prototype builds andproduction and should have capability to use such materialfor die casting,please provide a list of alloys typically usedWhat is the disposition process for the scraped castingparts? The scraped alloy? The alloy of gate system andoverflows?Subtotal0004.5 InspectionIs there a new product inspection proceedure for allincoming parts (PPAP-type inspection)? Are new partsbase-lined with 2-D drawing dimensional checks?Is there incoming inspection of the alloy?Does the supplier have the ability to check the alloycomposition during melting?Are there visual aides and gauges at the Operatorworkstations or Quality Inspection areas? Are theproceedures for using gauges and visual aides described inDoes the supplier have the check of package of castingparts?Does the supplier have the ability of inspection in house?CMM for the dimension measurement?Does the supplier have the ability of X-ray to check theporosity of FAE samples and for lot check during productionprocess?Does the supplier have the ability to provide the other tests,salt spray, painting/plating thickness check, etc?How are parts inspected during production? How often andusing what type of equipment?SubtotalTotalEvaluation Rate00000CTV-74-005-13
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CommScope, Inc. Confidential
07 Oct 2011
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