supplier evaluation (qvr)rev6 0112
DESCRIPTION
For new BusinessTRANSCRIPT
Supplier Evaluation / QVR AssessmentWorkbook Index
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Special Processes: AIAG CQI-9 Heat Treat System Assessment CQI-11 Plating System Assessment CQI-12 Coating System Assessment
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CQI-15 Welding System Assessment CQI-17 Soldering System Assessment
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Document Change Summary
Instructions
QVR / Supplier Evaluation Scoring
QVR Process Map
Cover (sheet)
Supplier Evaluation Summary
Quality
Delivery
Support & Technology
Cost
Print Review
CQI-9 Instructions for Cover Sheet CQI-11 Instructions for Cover CQI-12 Cover Sheet Instrts.
CQI-9 Cover Sheet CQI-11 Cover Sheet CQI-12 Cover SheetCQI-9 Elements, Sec. 1-3 CQI-11 Sections 1 & 2 General CQI-12 Section 1 & 2 GeneralCQI-9 Job Audit, Sec. 4 CQI-11 Sect. 3 ZN-ZN Alys. Eq. CQI-12 Job AuditCQI-9 Assessor's Qual. Reqs.. CQI-11 Section 4-DECO Equip. CQI-12 Assessor's Quals.CQI-9 Process Table A CQI-11 Section 5 Job Audit CQI-12 Process Table ACQI-9 Process Table B CQI-11 Assessor's Quals. CQI-12 Process Table BCQI-9 Process Table C CQI-11 Process Table A CQI-12 Process Table CCQI-9 Process Table D CQI-11 Process Table B CQI-12 Process Table DCQI-9 Process Table E CQI-11 Process Table C CQI-12 Process Table E
CQI-11 Process Table D CQI-12 Process Table FCQI-11 Process Table E CQI-12 Process Table GCQI-11 Process Table F CQI-12 Process Table H
CQI-12 Process Table ICQI-12 Process Table J
CQI-15 Cover Sheet Instrts CQI-17 Cover Sheet Instrts.CQI-15 Cover Sheet CQI-17 Cover SheetCQI-15 Elements Section 1 - 5 CQI-17Sect. 1&2 - Gen. OverviewCQI-15Job Audit Section 6 Proc. CQI-17 Section 3 - EquipmentCQI-15 Arc Welding Table A CQI-17Section 4 - Job AuditCQI-15 Resist.Welding Table B CQI-17Proc. Tab. A Paste Print.CQI-15 Laser Welding Table C CQI-17 Process Table B Insp.CQI-15Solid State Weld. Table D CQI-17Proc. Tab. C Surface Mnt
CQI-17 Proc. Table D ReflowCQI-17 Proc. Table E Glue Disp.CQI-17 Proc. Table F FluxCAI-17 Proc. Table G Pre-HeatCQI-17 Proc.Table H WaveCQI-17 Proc. Table I FountainCQI-17Proc. Tab.J Dip SolderingCQI-17Proc Tab. K Select. Sold.CQI-17Tab. L Auto Iron SoldingCQI-17Tab. M Man.l Iron Solder CQI-17Tab. N Laser & Soft Beam CQI-17 Tab. O Induction CQI-17Tab. P Conform. Coat&Tst CQI-17 Tab. Q PCB SeperationCQI-17Tab. R In-circuit TestingCQI-17 Tab. S Re-work
Supplier Evaluation (QVR) Change Summary (Rev. 6.0)1 Changed to Input-Process-Output (IPO) type format. Provided additional clarity to a couple of steps of the process.
1 Entire Supplier Evaluation is segregated into 4 key critical areas: Quality, Delivery, Support & Technology, and Cost .2 Counter on the Supplier Evaluation Score Summary page that displays total non-conformances by severity: either Major or Minor.
ANY element scored less than "7" will FAIL the entire audit. Additionally, a collective (total) score below 70%will also Fail the audit.
3 There are an areas findings sheet for each section. Any line item question that scores below 70% will automatically be displayed onthese findings sheets.
Deleted by Revision 5 dated July 15, 2010.4 A button has been added to take you directly to the AIAG Special Processes worksheets. By clicking 'YES" on the "COVER PAGE" you
will be immediately forwarded to the desired Special Processes Worksheet. If your facility doesn't handle any "SPECIAL PROCESSES" thenyou can depress the "NO" button on the "COVER PAGE" you will be asked to delete the corresponding worksheets, as they will not be required. This also reduces the size of the Supplier Evaluation / QVR Worksheet.
5 Have added the ability to answer "YES" or "NO" to each of the questions. If you answer "YES", the ranking defaults to "7" in the score; if youanswer "NO", the ranking defaults to "6". This allows you to answer a specific question without influencing the rest of the sections.NOTE: If the supplier has not satisfied any of the audit question, please label as "ZERO" (0), versus "NO".
6 You may also type in N/A for those areas that do not apply to this supplier. Notice that the "TOTAL POINTS POSSIBLE" will not change, soas to not penalize the supplier.
7 A supplier should receive a score of 7 if they meet the minimum requirements of a question. However if the supplier excels in an area, you mayreward them with the score of 8, 9, or 10. Any score over 7 will not increase the points possible.NOTE: Bonus points cannot improve any section over 100%.
a. Cover page altered to reflect areas of non-conformances (Quality, Delivery, Support & Technology, and Cost). b. Areas highlighted in "YELLOW" on the cover page and audit reports are the only cells that you may key information into.
Exceptions are in areas noted that may be overwritten as required. Example is 3d below.c. Have added area to show Corporate Addresses and phone numbers. The corporate area will autopopulate when you fill in the 'Manufacturing
Site' information. If the addresses are different, you still have the ability to overwrite the corresponding cells as needed.d. Bottom left hand corner displays whether or not a follow up audit will be required. This area is autopopulated, however may
be overwritten as needed.
a. Any finding with a ranking of less than 7 equates to a FAILED Supplier Evaluation / QVR Assessment.b. Supplier Evaluation totals below 70% equals a FAILED Supplier Evaluation / QVR Assessment.c. Any section / critical area as described above that falls below 70% equals a Failed Supplier Evaluation/QVR Assessment.
Revised to clarify language and responsibility (Process Map), and add Enviromental elements back in (omitted with Rel. 1.2)
Revised to add requirement for 'All applicable issues identified…" to be resolved (closed) PRIOR to Sourcing on 'Instructions' and 'QVR Scoring Key' worksheets.
A. PROCESS MAP:
B. SUPPLIER ASSESSMENT WORKSHEET
C. COVER PAGE:
D. PARAMETERS FOR WORKSHEET:
Remy Inc.This document has been reviewed and approved by authorized personnel.
Approval date and name are recorded electronically in the document control system. The electronic version is the only controlled copy.
Rev. Level 3.5RCP-740
Supplier Evaluation (QVR) Overview
Purpose:
Application:
Instructions:
A general overview of the process is illustrated on the next worksheet of this file; reference
Note: For Remy internal use, refer to RCP-741 QVR Survey Letter.
Process Owner:Supplier Quality Department
To evaluate a potential supplier's process and procedures for effectiveness and capability for maintaining a high level of quality of potential purchased components.
The acronym 'QVR' stands "Quality, Value, Responsiveness", and is frequency used within Remy to be synonymous with a 'Supplier Evaluation' or 'Potential Supplier Assessment'.
The potential supplier will be given a rating from the Remy Supplier Quality Engineer upon completion of the assessment.
The Supplier Evaluation may be applicable whenever the project requires new suppliers and / or new parts.
The Program Manager, Purchasing Commodity Manager, or Supplier Quality Manager shall determine applicability for the specific supplier or component.
Prior to an on-site review, the responsible Remy Commodity Manager shall request the potential supplier to complete a Supplier Self-Assessment survey (Appendix C), located on the Remy Supplier web-page (http://www.remyinc.com/suppliers_manual.asp).
Upon receipt of the completed survey, Remy key-stakeholders (Commodity Mgr., Supplier Quality, Program Mgr.) will review the information provided and determine whether to proceed with an on-site evaluation. If so, the supplier will be contacted by Remy to coordinate an on-site verification of the supplier's capabilities.
The Cover page and QVR Survey are to be completed by Supplier Quality Engineer (or delegate). The cover summarizes the results of the QVR process audit for the specific supplier and part on the given date. The Survey provides the detailed assessment criteria for rating.
NOTE: ALL applicable issues identified (i.e. scores <7) MUST be resolved prior to Sourcing.
The Print Review Process may be utilized, at the discretion of the Supplier Quality Engineer and PDRE, when part prints (part numbers) for a given potential supplier are known at the time of the on-site assessment. This process may also be utilized at other times during the development process.
The results of the QVR Review will be maintained by the Supplier Quality Department (within the Remy PPAP Tracking System application). A non-controlled copy of the cover page may be filed in the program folder to provide program documentation.
QVR Process Map
SUPPLIER EVALUATION SCORING GUIDELINES Score
0
1
2
3
4
Implementation has progressed (60-80% complete) and there is preliminary evidence of relevant results. 5
6
7
8
9
10
Supplier is not familiar with the requirements of the element and has no relevant source documentation (flow charts, forecasts, plans, procedures, strategies, etc.) in this area.
Supplier is familiar with the requirements of the element, but there is no evidence of source documentation, planning, or implementation.
Supplier is familiar with the requirements of the element, and has preliminary source documentation with incomplete plans for implementation.
Source documentation is available. Implementation (with assigned responsibilities) has just started, (0-30% complete).
Source documentation is available and implementation is in progress (30-60% complete). Deficiencies have been identified but improvements are not quantifiable.
Implementation is nearly complete (80-95% complete) and documented evidence of implementation effectiveness exists.
Full implementation of source documentation for the requirement and complete confirmed evidence of implementation effectiveness. The supplier has met minimum requirements.
Analysis of results and on-going continuous improvement can be demonstrated in key areas linked to customer satisfaction.
Supplier has reached world class performance and is able to show growth beyond ISO-9000and TS16949 requirements and continuous improvement in all areas.
Supplier is "best-in-class" and is able to demonstrate significant innovation in new ways to show relevant results beyond the customer requirements. The supplier set the industry benchmark.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
Supplier Evaluation Audit - Release 1.2 APPROVAL STATUS: NOT APPROVED Score: Fail
Individual Section Performance
FAIL 41%
FAIL 10%
Date Completed: FAIL 24%
FAIL 25%
Supplier Information
MANUFACTURING SITE CORPORATE SITE
Supplier's Name: Corporate Headquarters:
Street Address: Address:
City, State: City, State:
Zip code (or Mail Code): Zip code (or Mail Code):
Country: Country:
Telephone #: Corp. E-mail Address
Fax: SCAR Primary Contact Name
Commodity and/or Phone and Fax #
Service Provided: Email Address
SPECIAL PROCESSES (REF. AIAG GUIDELINES) Phone and Fax #
Email Address
Heat Treat Services Provided [YES / NO]
Plating Services Provided [YES / NO]
Coating Services Provided [YES / NO]
Welding Services Provided [YES / NO]
Soldering Services Provided [YES / NO]
Key personnel completing this survey:
SUPPLIER REPRESENTATIVES: REMY REPRESENTATIVES:
Name: Title Name: Title
Does this location have a quality system certification? ISO 9001:2000
Certificate Number Expiration Date: ISO/TS16949
Registrar
Certification Body Other (identify)
Follow-up Audit Required? Person responsible for audit corrective actions: Survey corrective action due date:
YES
The results of this audit have been explained to the supplier to the extent that expectations are understood.
Remy Representative Signature Supplier Representative Signature
QUALITY
DELIVERY
SUPPORT & TECH.
COST
SPECIAL PROCESSES
COMPLETE WORKSHEET AS
REQUIRED
Click Yes or No in Box Provided
PPAP Primary Contact Name
CQI-9 Heat Treat-SP1
CQI-11 Plating - SP2
CQI-12 Coating - SP3
CQI-15 Welding - SP4
CQI-17 Soldering - SP5
ISO14000
NOTE: ALL "open" issues identified MUST be resolved PRIOR to Sourcing.
YES
YES
NO
NO
NO
YES
YES
YES
NO
NO
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES RED MinorSums SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Qu
alit
y
Q-1 Quality System Capability 30 M 0 FAIL 1 2Q-2 Internal Audit 50 M 0 FAIL 2 3
Q-3 30 M 0 FAIL 1 2Q-4 APQP 30 M 0 FAIL 1 2Q-5 PPAP 40 M 0 FAIL 2 2Q-6 Document Control System 30 M 0 FAIL 1 2Q-7 Training Records 40 M 0 FAIL 1 3Q-8 Final Inspection 60 M 0 FAIL 2 4Q-9 Process Control 60 M 0 FAIL 2 4
Q-10 Nonconforming Material Control 30 M 0 FAIL 2 1
Q-11 50 M 0 FAIL 2 3Q-12 Supplier Control 40 M 0 FAIL 2 2
0.00% Q-13 Control of Supplied Material 20 M 0 FAIL 1 1 ###
Del
iver
y
D-1 100 M 0 FAIL 2 80.00% D-2 Material ID and Traceability 30 M 0 FAIL 3 0 ###
S-1 30 0 FAIL 0 3
S-2 Technical Capability 110 M 0 FAIL 5 6
S-3 Housekeeping 40 0 FAIL 0 4
S-4 Facility Security- All Required 40 M 0 FAIL 4 0
0.00% S-5 Information systems 80 M 0 FAIL 8 4 ###
Co
st
C-1 Lean Manufacturing 50 0 FAIL 0 5C-2 Preventive Maintenance Program 40 M 0 FAIL 2 2
C-3 150 M 0 FAIL 5 100.00% C-4 Business Management Systems: Materials 70 0 FAIL 0 7 ###
All Section Totals 1250 M 0 FAIL 49 80 0
NOTE: Only areas in dull yellow are editable
Total Points Possible for a World Class
Supplier
M = Major
SCOREMajor Sums
Note: Score in accordance with
AIAG "Quality System
Assessment" manual unless
otherwise noted.
Corrective & Preventative action system
Control of Inspection, Measuring, and Test Equipment (IMTE)
Dock Storage, Material Handling, and Packaging
Su
pp
ort
&
Tec
hn
olo
gy Process/ Tool/ Die/ Jig/
Fixture/ Part Design Control
Business Management Systems:Production Capacity, Planning, and Scheduling
Cover PageCover Page
Index PageIndex Page
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Q-1 Quality System Capability 30 M 0 FAIL RED SCORE <7
1 10 M 0 REDIs the supplier certified to any Quality System?
1
2 10 0 RED 1
3 10 0 RED 1
Q-2 Internal Audit 50 M 0 FAIL RED SCORE <71 Is there a current Internal Audit schedule? 10 M 0 RED 12 Are audits conducted as scheduled? 10 M 0 RED 1
3 10 0 RED 1
4 10 0 RED 1
5 10 0 RED 1
Q-3 30 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 0 RED 1
3 10 0 1
Q-4 APQP 30 M 0 FAIL RED SCORE <71 Does the supplier have a formal / documented APQP process? 10 M 0 RED 1
2Does the supplier have a standard form to document APQP requirements?
10 0 RED 1
3 10 0 RED 1
Total Points Possible for a World Class
SupplierSCORE
Amt. Of Major
Findings
Amt. of Below 70%
Observations
Is the supplier TS-16949 Certified? If No do they have a plan to achieve TS-16949 Certification?
Is there access to e-mail and the World Wide Web provided for those individuals with Quality and Management responsibilities?
Is the key quality contact for the plant location accessible via telephone (either land line or cell phone) and Email?
Are there regular (at least monthly) standard work audits that are cascading and performed by leadership?
For any Internal Corrective Action (ICAR) is there a functional management review procedure in place.
Are corrective actions and follow-up carried out to verify that actions taken are effective?
Corrective & Preventative action system
Does the supplier's process require documentation of the non-conformance (7-Step or 8D), containment and inspection of affected material when a non-conformance is found either by the supplier or the customer?
Does the supplier have a corrective action system and use analysis tools such as A3 Story-Board, 8D, 7D, 7 step, 5 phase, etc.?
Has the supplier been placed in a controlled shipment or New business hold status with the last 6 months? Answer "Yes Or No"
Is there evidence that a system exists to support design, procure, manufacture, develop, and implement new production tooling (i.e. Gantt charts, supplier selection, tool validation/runoff, PPAP/runoff at manufacturing location)?
Cover PageCover Page
Index PageIndex Page
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Q-5 PPAP 40 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 M 0 RED 1
3The supplier shall have the AIAG electronic version of PPAP documentation
10 0 RED 1
4 10 M 0 RED 1
Q-6 Document Control System 30 M 0 FAIL RED SCORE <7
1 10 0 RED 1
2 10 M 0 RED 1
3 10 0 RED 1
Q-7 Training Records 40 M 0 FAIL RED SCORE <7
1 10 0 RED 1
2 10 0 RED 1
3 10 0 RED 1
4 10 M 0 RED 1
Q-8 Final Inspection 60 M 0 FAIL RED SCORE <7
1 10 0 RED 1
2 10 0 RED 1
3 10 0 RED 1
4 10 M 0 RED 1
5 10 0 RED 1
6 10 M 0 RED 1
Points Possible SCORE Sum of
MajorsSum of Section
NC
Are appropriate procedures in place for preparation of PPAP documentation in accordance with AIAG guidelines?
Are there approved customer PPAP's on file that correlate to the current revision of prints being used for production?
The Supplier must have an IMDS account and at least 1 trained person. Answer YES or NO.
Is there a master list(s) of all controlled documents (or acceptable alternative) readily available which indicates document approval status and revision?
Are all changes (revisions) identified on each document and do these revision notes indicate the purpose/reason for the change? (includes control plans, process flow diagrams, and PFMEA's).
Is there a system in place to track when changes are implemented relative to production parts?
Are records available to show that production operators have been trained in their operations?
Are employee training needs documented and are records of completed training maintained?
Are there specific training records documenting operator training in processes necessary for the commodity being considered?
Is there objective evidence that all personnel are trained using the company procedure for emergency, unplanned shutdowns and power outages (including quarantine and inspection of materials made before, during and after the emergency)?
Does the supplier carry out final inspection and testing in accordance with the quality plan (Control Plan) and/or documented procedures?
Does the supplier hold product until the required inspections and tests have been completed or necessary reports have been received and verified, except for release under positive recall?
Does the supplier conduct scheduled audits of the packaged final product to verify conformance to all specified requirements.
Does the supplier maintain records which provide evidence that the product has been inspected and/or tested, clearly showing whether the product has passed or failed inspection based on the defined acceptance criteria, and identifying the authority responsible for the product release?
Are first piece inspected parts retained until final data is complete to enable traceability to raw data?
Are set-up and partially finished first piece sample inspected parts scrapped after final data is complete? If those parts are finished and not scrapped is there a control system in place to assure they are properly finished to specification. These parts must be identified, contained and separately inspected and released.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Q-9 Process Control 60 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 M 0 RED 1
3 10 0 RED 1
4 Is inspection data from the process recorded? Are records available? 10 0 RED 1
5 10 0 RED 1
6 10 0 RED 1
Q-10 Nonconforming Material Control 30 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 M 0 RED 1
3 10 0 RED 1
Q-11 50 M 0 FAIL RED SCORE <7
1 10 0 RED 1
2 10 M 0 RED 1
3 10 M 0 RED 1
4 10 0 RED 1
5 10 0 RED 1
Total Points Possible for a World Class
SupplierSCORE Sum of
MajorsSum of Section
NC
Are individual operations specified by detailed work and inspection instructions that are readily available? (I.e. drawings showing process steps, standardized format, photos of actual process steps)
Do the supplier's procedures require approval of processes and equipment after set-ups, tool changes, prior to actual use? Are there specified criteria for first piece approval?
Are workmanship standards defined by written specifications, photographs, and / or labeled boundary samples that are readily available to the operator?
Is SPC used to track variability in the process for controlling process parameters? Are corrective actions recorded for out of control conditions?
Does the supplier have a document that explains in detail the type of machines and sizes for each operation (s) that will be used for the commodity being requested? Is it readily available?
Do the supplier's procedures require isolation, containment, and visual identification of nonconforming material sufficient to prevent unauthorized use and/or shipment?
Are the non-conforming materials isolated and identified per the above procedure so that they are not used or shipped?
Does the supplier have a documented procedure for immediate customer notification in the event that it is suspected that nonconforming material may have been shipped?
Control of Inspection, Measuring, and Test Equipment (IMTE)
Is special or final test equipment verified after set-up, maintenance, and changeover?
Is the calibration of each piece of IMTE verified at prescribed intervals, against certified equipment traceable to recognized international or national standards?
Are IMTE calibration operations carried out in an appropriately controlled environment? Are there records to verify this?
Are appropriate records kept of IMTE calibration that include the type of equipment, identification, location, frequency of calibration, verification method, acceptance method, and any necessary corrective action?
Does the calibration system include employee-owned equipment used for product inspection?
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Q-12 Supplier Control 40 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 0 RED 1
3 10 0 RED 1
4 10 M 0 RED 1
Q-13 Control of Supplied Material 20 M 0 FAIL RED SCORE <7
1 10 M 0 RED 1
2 10 0 RED 1
Total Points Possible for a World Class
SupplierSCORE Sum of
MajorsSum of Section
NC
Are suppliers selected and evaluated based on their ability to meet quality system and quality assurance requirements?
Are records maintained of supplier performance to quality system, delivery, and product quality requirements, including appropriate corrective actions?
Are on-site assessments of supplier capabilities performed and documented as appropriate? Note; commercially available or trade name items are exempt.
Are special processes such as heat treat, plating, or coating subcontracted? (separate QVR must be used if sub-contracted) Has the HT survey been performed and Passed? HT, Plating and coating suppliers must have ISO14000 or Use Environmental Self Survey and approval by Remy Corp EH&S.
Does the supplier's receiving quality system use at least one of the following methods to qualify product prior to use: (1) evaluation of supplier statistical data, (2) receiving inspection and/or testing, (3) combination of supplier quality system assessments and supplier quality performance history, (4) third party product evaluation/testing?
Are material storage areas clean, well organized, and sufficiently maintained to (1) preserve traceability information, (2) prevent damage, and (3) prevent contamination with undocumented or uninspected goods?
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS SUPPLIER ACTIONS RESP DUE
Q-1 Quality System Capability 30 M 0 FAIL RED SCORE <7 1 2Q-2 Internal Audit 50 M 0 FAIL RED SCORE <7 2 3
Q-3 30 M 0 FAIL RED SCORE <7 1 2
Q-4 APQP 30 M 0 FAIL RED SCORE <7 1 2Q-5 PPAP 40 M 0 FAIL RED SCORE <7 2 2Q-6 Document Control System 30 M 0 FAIL 1 2Q-7 Training Records 40 M 0 FAIL RED SCORE <7 1 3Q-8 Final Inspection 60 M 0 FAIL RED SCORE <7 2 4Q-9 Process Control 60 M 0 FAIL RED SCORE <7 2 4
Q-10 Nonconforming Material Control 30 M 0 FAIL RED SCORE <7 2 1
Q-11 50 M 0 FAIL RED SCORE <7 2 3
Q-12 Supplier Control 40 M 0 FAIL RED SCORE <7 2 2Q-13 Control of Supplied Material 20 M 0 FAIL RED SCORE <7 1 1
Quality Section Total 510 M 0 FAIL 0.00% 20 31*Only areas in dull yellow are editable*
Total Points Possible for a World Class
SupplierSCORE Sum of
MajorsSum of Section
NC
Corrective & Preventative action system
Control of Inspection, Measuring, and Test Equipment (IMTE)
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
*Only areas in dull yellow are editable*
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE
D-1 100 M 0 FAIL
1 10 0 RED
2 10 0 RED
3 10 0 RED
4 10 M 0 RED
5 10 0 RED
6 10 0 RED
7 10 0 RED
8 Is the dock clean and orderly? 10 0 RED
9 10 0 RED
10 10 M 0 RED
D-2 Material ID and Traceability 30 M 0 FAIL
1 10 M 0 RED
2 10 M 0 RED
3 10 M 0 RED
Total Points
Possible for a World
Class Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Dock Storage, Material Handling, and Packaging
Is there a material handling and storage system in use that adequately preserves part quality and integrity during the production process (i.e. correct size and weight containers, adequate for projected lot sizes and pulls, protection against elements (rust, corrosion, physical damage, contamination, and equipment available to safely move containers from operation to operation.)?
Does this system capture net and gross weight of individual and packaged components?
Evaluate the inventory management system and it's ability to optimize inventory turns, assure stock rotation and minimize inventory levels?
Evaluate the system which assures material that has passed final inspection and is packaged for shipment, is labeled and identified correctly?
Does the supplier control the packing, packaging and marking processes so as to ensure product conformance to specifications?
Are materials shipped in conformance with the customer requirements adhering to up-to-date customer specified transportation mode and routings?
Does the supplier have a computerized system for receiving customer planning information and ship schedules and Advanced Shipping Notifications (ASN'S), unless waived by the customer?
Are there adequate storage areas for WIP and finished goods? (i.e. adequate for projected lot sizes and pulls, protection against elements, equipment necessary for safe moves of product)
Is there a system in place that allows for UPS, FED X, or DHL orders to be received or shipped as necessary.
Does identification of purchased materials and their records maintain traceability to material certifications and test reports?
Do records show that lot identity and disposition are maintained throughout the supplier's manufacturing and delivery process to assure lot integrity and traceability to materials used and processes performed?
Do process records adequately reflect process and inspection status throughout the system, including storage and in-process holding areas?
Cover PageCover Page
Index PageIndex Page
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE
D-1 100 M 0 FAIL
D-2 Material ID and Traceability 30 M 0 FAILDelivery Section Total 130 M 0 FAIL 0
*Only areas in dull yellow are editable*
Total Points
Possible for a World
Class Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Dock Storage, Material Handling, and Packaging
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE
S-1 30 0 FAIL
1 10 0 RED
2 10 0 RED
3 10 0 RED
S-2 Technical Capability 110 M 0 FAIL
1 10 M 0 RED
2 10 0 RED
3 10 M 0 RED
4 10 0 RED
5 10 0 RED`
6 10 M 0 RED
7 10 0 RED
8 10 0 RED
9 10 M 0 RED
10 10 M 0 RED
11 10 0 RED
S-3 Housekeeping 40 0 FAIL
1 10 0 RED
2 10 0 RED
3 10 0 RED
4Are all Indirect materials clearly identified and placed in areas designated.
10 0 RED
Total Points
Possible for a
World Class
Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Process/ Tool/ Die/ Jig/ Fixture/ Part Design Control
Are records available of formal documented design reviews by the appropriate functions conducted at appropriate stages of design per the design plan?
Are design changes identified, documented, reviewed and approved by authorized personnel before implementation?
Does the supplier have documented procedures for controlling customer documents, i.e., drawings and specifications?
Does the supplier have relevant experience with the commodity or service being considered?
Do the supplier's current processes and equipment require improvement or development to manufacture the product or perform the service being considered?
For Special characteristics, does the supplier perform capability studies on new and ongoing processes? There must be evidence that on-going processes are capable.
Does the supplier have access to product or tooling development in-house or with a parent company?
Are all required inspection devices on site to inspect Remy parts to validate engineering specifications?
Are there qualified manufacturing engineering and technical resources available to support the commodity being considered?
Does the supplier have resources available for the support of tool and gage design and fabrication? (ex. Computer aided design system, tool room, EDM capabilities, as necessary.)
Is there a method to capture Tooling cost, tool life, and tool description for each operation. Is it available for review?
Are there specific Quality Assurance Engineering and other technical resources available necessary to support the commodity being considered?
Is there evidence that a system exists to design, develop, and implement new production quality plans and systems for the commodity being considered? (i.e. Gantt or MS Project, preliminary process flow, preliminary PFMEA, preliminary Control Plan, capability studies, gage R&R, PPAP, and gaging instructions.)
Does the supplier possess the applicable heat treat and/or plating specifications and necessary inspection equipment?
Is the supplier's plant layout clean, efficient, organized, and well lighted with demonstrated evidence of "good housekeeping" being practices throughout the manufacturing process?
Lighting should be sufficient to carry out visual work and recording at or near the activity. IS it?
Operations should be organized to facilitate good material flow and minimize the potential for handling damage to occur.
Cover PageCover Page
Index PageIndex Page
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE
S-4 Facility Security- All Required 40 M 0 FAIL
1 10 M 0 RED
2 10 M 0 RED
3 10 M 0 RED
4 10 M 0 RED
S-5 Information systems 80 M 0 FAIL
1 10 M 0 RED
2 10 M 0 RED
3 10 M 0 RED
4 Does the supplier have a disaster recovery plan? 10 M 0 RED
5 10 0 RED
6 10 0 RED
7 10 0 RED
8 10 0 RED
End
Total Points
Possible for a
World Class
Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Are all external and internal doors, windows, gates, and fences protected with locking devices adequate to prevent unauthorized entry?
Is the physical security of international, domestic, high-value, and dangerous goods cargo assured by being properly marked, and segregated within the warehouse by use of a safe, caged, or otherwise fenced-in area?
Is unauthorized access to the shipping, loading dock and cargo areas prohibited? Controls must include the positive identification of all employees, visitors and vendors.
Are there measures in place requiring proper storage of empty and full containers to prevent unauthorized access?
Does the supplier have the capability to respond to Remy with a “Ship To” date based on the initial order over the Internet within 24 hours?
When the supplier receives the forecast, is there a system in place to measure performance against it?
Do you have a system that communicates your demand signals to your suppliers?
Do you have a network infrastructure/bandwidth system that exists to support manufacturing and business processes?
Are the following: Smoke Detection and Fire Suppression resident at this site?
How do you segregate customer specific data and information within your systems.
Does the supplier use any special security "firewall"/encryption solutions to securely communicate with your customers any sensitive information?
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M=Major SCORE RED SDE COMMENTS RESP DUE
S-1 30 0 FAILS-2 Technical Capability 110 M 0 FAILS-3 Housekeeping 40 0 FAILS-4 Facility Security- All Required 40 M 0 FAILS-5 Information systems 80 M 0 FAIL
Support Section Total 300 M 0 FAIL 0.00% *Only areas in dull yellow are editable*
End
Total Points
Possible for a
World Class
Supplier
SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Process/ Tool/ Die/ Jig/ Fixture/ Part Design Control
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M = Major RED SDE COMMENTS RESP DUE
C-1 Lean Manufacturing 50 0 FAIL RED SCORE <7C.1.1 Is the factory layout designed to support Lean Manufacturing? 10 0 RED
C.1.2 10 0 RED
C.1.3 Is the supplier working in cells? 10 0 REDC.1.4 Is the supplier practicing one-piece flow concept? 10 0 REDC.1.5 Is the work in process on a pull system? 10 0 REDC-2 Preventive Maintenance Program 40 M 0 FAIL RED SCORE <7
C.2.1 10 M 0 RED
C.2.2 10 0 RED
C.2.3 Does the supplier monitor equipment uptime/downtime? 10 0 RED
C.2.4 10 M 0 RED
C-3 150 M 0 FAIL RED SCORE <7
C.3.1 10 0 RED
C.3.2 10 0 RED
C.3.3 10 M 0 RED
C.3.4 10 M 0 RED
C.3.5 10 M 0 RED
C.3.6 10 M 0 RED
C.3.7 10 0 RED
C.3.8 10 0 RED
C.3.9 10 0 RED
C.3.10 10 M 0 RED
C.3.11 10 0 RED
C.3.12 10 0 RED
C.3.13 10 0 RED
C.3.14 10 0 RED
C.3.15 10 0 RED
Total Points Possible for
a World Class
Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Is the supplier practicing lean concepts for product and process development?
Is there a schedule of planned maintenance on all machinery, tooling, and equipment in the process?
Are records available for all maintenance activities planned and unplanned? Root cause and corrective action should be included in unplanned maintenance records?
Is there a clearly defined and documented plan for emergencies, unplanned shutdowns and power failures? Plan must include responsibilities, evacuation procedure, re-start and quarantine/inspection of materials produced before, during and after the emergency/failure.
Business Management Systems:Production Capacity, Planning, and Scheduling
Can the supplier demonstrate that their production planning methodology is capable of satisfying customer demands- 100% on-time shipments.
Is there evidence of corrective action taken when delivery schedule compliance is less than 100% on-time?
Is the production forecast process automated or is it currently supported by a manual Forecast process?
Is this someone who reviews the forecast? Is there a process to approve the response prior to commitment to the customer.
Describe your daily production planning process and review. Is there a documented system available and is it being followed.
How do you track/ review / measure performance to schedule/ commit. Is this used as a planning tool?
What process safeguards exist to track product through-put and status? Is documented system being followed?
How do you support short term upside requests and what incremental capacity level is maintained? Is system being followed?
What long term capacity limitations exist for this site (Raw/Manufacture etc). Is there an contingency plan for production to be completed in the event of an emergency?
Is there a procedure to determine the quantity of equipment, size and physical plant layouts. to complete weekly production volumes without serious detriment to overall operations and part quality? Current capacity utilization is ~40%, based on a __hours, __shift, __ days per work week.
How and when are risks/misses communicated to your customer, mgmt? Is the system documented and followed?
Does the supplier have a system in place that determines if the operations will be completed in house or sub-let? Is it documented?
Does the supplier have a system (Documentation) in place that captures, labor rate per hour per operation, manning requirements at each operation, set up costs at each operation, and other fixed and variable costs associated with each operation? Is this readily available to review?
Does the supplier have a system in place that reviews all associated operations costs; (i.e.raw material, packing, packaging, scrap, and transportation) that displays that costs and goals are being met? Is this document available for review?
Does the supplier have a system that calculates expenses and profits associated with SG&A (Sales, General & Administration)
Cover PageCover Page
Index PageIndex Page
Supplier Evaluation Audit - Rel. 5.0 Release date: 19-July-2010
REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE
C-4 Business Management Systems: Materials 70 0 FAIL RED SCORE <7
C.4.1 10 0 RED
C.4.2 10 0 RED
C.4.3 Is there a procedure and process for an escalation path for part shortages? 10 0 RED
C.4.4 10 0 RED
C.4.5 10 0 RED
C.4.6 Is there a documented process to perform cycle counts? Is it used? 10 0 RED
C.4.7Is there a Corrective Action Process in place for inventory non-conformances
10 0 RED
REQUIREMENT CATEGORIES M=Major RED SDE COMMENTS RESP DUE
C-1 Lean Manufacturing 50 0 FAILC-2 Preventive Maintenance Program 40 M 0 FAIL RED SCORE <7
C-3 150 M 0 FAIL RED SCORE <7C-4 Business Management Systems: Materials 70 0 FAIL
Cost Section Total 310 M 0 FAIL 0.00%*Only areas in dull yellow are editable*
Total Points Possible for
a World Class
Supplier
SCORE SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Does the company have strategic objectives for materials and supply chain management?
Is there a method to determine which items are purchased centrally and which from mfg. Site?
Does the supplier have a system that tracks the number of orders with on-time delivery (OTD) from their suppliers? What is the result during last 6 months?
Does the supplier have a system in place that confirms the product and quantities in their software, coorelates with the product quantities that are physically on the floor is correct?
Total Points Possible for
a World Class
Supplier
SUPPLIER ACTIONS
Note: Score in accordance with AIAG "Quality System Assessment" manual unless otherwise noted.
Business Management Systems:Production Capacity, Planning, and Scheduling
REMY INTERNATIONAL, INC. Supplier QVR Source Evaluation Audit
Part Number
The proposed parts that the supplier will produce must be reviewed with representatives present from the following functional areas.
1 Is there consensus that ALL dimensions and features are manufacturable?Note Exceptions:
Yes2 Is there consensus that all dimensions are properly tolerance?
Note Exceptions:
Yes3 Is the part designed optimally for the process and material?
Note Exceptions:
Yes4 Is the part dimensioned properly to allow for proper gaging (correct datums and basic dimensions)?
Note Changes Required:
Yes5 Is gaging available to measure all features shown on the print?
Note Exceptions:
Yes6 Is there a clear understanding that all KPC items will require a CPK of 1.67 or greater?
Note Exceptions:
Yes7 Is GR&R known for gages that will be used for KPC’s? (must be less than or equal to 10%)
Note Exceptions and GR&R value:
Yes8 Does the supplier have access to the applied specifications (Paint, Materials, Plating, Heat Treatment Etc)
What do they need?:
Yes9 Have the DFMEA items for this part been reviewed with the supplier?
List Items:
Yes10 Does the Supplier have a preliminary process flow established? Is it acceptable to Remy?
Note Exceptions:
Yes
Part Print Review
• Supplier’s Manufacturing Representative• Supplier’s Quality Engineering
• Remy Production Engineering • Remy Supplier Quality • Supplier’s Raw Material and Sub-Suppliers
Cover PageCover Page Index PageIndex Page
CQI-9 HEAT TREAT SYSTEM ASSESSMENTInstructions for completing the Cover Sheet
1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physicallocations in the same general area. If there is a separate management team (Quality Manager andMetallurgist) or different management system, then these locations shall be considered asseparate facilities.
2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
4 Fax number: The fax number of the facility.
5 Number of Heat Treat Employees at this Facility: The number of employees, salaried and hourly, associated with the Heat Treat operation at this facility.
6 Captive Heat Treater (Y/N): Enter "Y" if this facility heat treats components for their own company. Enter"N" if the company does not Heat Treat any components for their own company.
7 Commercial Heat treater (Y/N): Enter "Y" if this facility Heat Treats components for companies other thantheir own company. Enter "N" if this facility does not Heat Treats any components for other companies.
8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.Example: May 3 -- 4, 2006.
9 Date of Previous Assessment: List the date of the previous CQI-9 Special Process: Heat TreatSystem Assessment of this facility.
10 Type(s) of Thermal Processings at this Facility: Place a checkmark to designate the thermal process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the Heat TreatSystem Assessment.
11 Current Quality Certification(s): the heat treater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the heat treater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 4, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the plater's organization.
14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
Cover PageCover Page Index PageIndex Page
Special Process: Heat Treat System Assessment
Facility Name:Address:
Phone Number: Type(s) of Thermal Processing at this Facility:Fax Number: Process Table A - Ferrous
CarburizingNumber of Heat Treat Employees at this Facility: Carbonitriding
Carbon CorrectionCaptive Heat Treater (Y/N): Neutral Hardening
Quench & TemperCommercial Heat Treater (Y/N): Austempering / Martempering
TemperingPrecipitation Hardening / Aging
Process Table B - FerrousNitriding (Gas)
Process Table C - AluminumAluminum Heat Treatment
Process Table D - FerrousInduction Heat Treating
Process Table E AnnealingNormalizingStress-Relieving
Current Quality Certification(s):
Date of Re-assessment (if necessary):
Personnel Contacted:Name: Title: Phone: Email:
0 00 00 00 0
Auditors/Assessors:Name: Company: Phone: Email:
000
Number of "Not Satisfactory" Findings:
Number of "Needs Immediate Action" Findings:
Number of "Fail" Findings in the Job Audit(s):
Date of Assessment:
Date of Previous Assessment:
Ferritic-Nitrocarburizing (Gas or Salt)
Cover PageCover Page Index PageIndex Page
Special Process: Heat Treat System Assessment
Assessment
Question Requirements and Guidance Objective Evidence N/A Satisfactory
Section 1 - Management Responsibility & Quality Planning
1.1
1.2
1.3
1.4
Question Number
Not Satisfactory
Needs Immediate Action
Is there a dedicated and qualified heat treat person on-
site?
To ensure readily available expertise, there shall be a dedicated and qualified heat treat person on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and heat treat knowledge. The qualifications shall include a minimum of 5 years experience in heat treat operations or a combination of a minimum of 5 years of formal metallurgical education and heat treat experience.
Does the heat treater perform advanced quality planning?
The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The heat treater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Are heat treat FMEA's up to date and reflecting current
processing?
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key heat treat process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
Are heat treat process control plans up to date and reflecting
current processing?
The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key heat treat process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables, Sections 3.0 and 4.0.
Index PageIndex PageCover PageCover Page
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
1.5
1.6
1.7
1.8
Are all heat treat related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.
To ensure all customer requirements are both understood and satisfied, the organization shall have all related heat treat and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards / specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.
Is there a written process specification for all active
processes?
The heat treater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.
Has a valid product capability study been performed initially and after process equipment has been relocated, or had a
major rebuild?
To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all heat treat processes per furnace line defined in scope of work & in accordance with customer requirements. A furnace line may include a combination of equipment that is integrated in the performance of a heat treatment process, e.g., hardening, quenching, and tempering. Capability study techniques shall be appropriate for the heat treat product characteristics, e.g., tensile strength, case depth, hardness. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.
Does the heat treater collect and analyze data over time,
and react to this data?
The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
Is management reviewing the heat treat monitoring system
every 24 hours?
Management shall review the furnace monitoring systems at intervals not to exceed 24 hours. The heat treat monitoring system includes but is not limited to temperature strip charts, atmosphere strip charts, computer data logs, furnace and operator logs, etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the furnace data shall be documented and this requirement also applies to computerized data.
Are internal assessments being completed on an annual
basis, at a minimum, using AIAG HTSA?
The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG HTSA.
Is there a system in place to authorize reprocessing and is
it documented?
The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual.The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible.Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary heat treat modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.
Does the Quality Department review, address, and
document customer and internal concerns?
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.
Is there a continual improvement plan applicable
to each process defined in the scope of the assessment?
The heat treater shall define a process for continual improvement for each heat treat process identified in the scope of the HTSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.
Does the Quality Manager or designee authorize the
disposition of material from quarantine status?
The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.
Are there procedures or work instructions available to the
heat treat personnel that define the heat treating
process?
There shall be procedures or work instructions available to heat treat personnel covering the heat treating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.
Is management providing employee training for heat
treating?
The organization shall provide employee training for all heat treating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
1.17
1.18
1.19
Section 2 - Floor and Material Handling Responsibility
2.1
2.2
2.3
2.4
Is there a responsibility matrix to ensure that all key
management and supervisory functions are performed by
qualified personnel?
The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.
Is there a preventive maintenance program? Is maintenance data being
utilized to form a predictive maintenance program?
The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization (see Section 1 of the Process Tables).Maintenance data shall be collected and analyzed as part of a predictive maintenance program.
Has the Heat Treater developed a critical spare part list and are the parts available
to minimize production disruptions?
The heat treater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.
Does the facility ensure that the data entered in the
receiving system matches the information on the customer's
shipping documents?
It is critical that all customer requirements and lot identification be adequately transferred to internal heat treat documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to captive heat treat departments. This process refers to receiving and shipping the parts in and out of the heat treat department.
Is product clearly identified and staged throughout the
heat treat process?
Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the heat treat process. Non-heat treated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.
Is lot traceability and integrity maintained throughout all
processes?
Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.
Are procedures adequate to prevent movement of non-conforming product into the production system?
The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming hold area shall be clearly designated to maintain segregation of such material.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
2.5
2.6
2.7
2.8
2.9
2.10
Is there a system to identify trap points in the entire heat
treat process to reduce risk of mixed parts (inappropriate,
non-heat treated, or improperly heat treated
parts)?
Heat-treating furnaces and other processing equipment contain areas that have a risk of trapping or holding parts. Such trapping of parts can lead to damage, improperly processed parts or lot mixing/contamination. A system shall exist to identify trap points in the entire heat treat process to reduce risk of mixed parts (inappropriate, non-heat treated, or improperly heat treated parts). The heat treater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.
Are containers free of inappropriate material?
Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming heat treated parts or inappropriate material contaminate the finished lot.
Is furnace loading specified, documented and controlled?
Furnace loading parameters shall be specified, documented, and controlled. Examples include feed rate, belt speed, number of parts per fixture, and load weight. Refer to Process Tables, Section 3.0, for frequency of checks.
Are operators trained in material handling,
containment action and product segregation in the
event of an equipment emergency including power
failure?
Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.g., loading, austentizing, quenching, tempering.
Is the handling, storage and packaging adequate to
preserve product quality?
Handling, storage, and packaging shall be adequate to preserve product quality. The heat treater’s furnace loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.Some equipment includes conveyors and other moving components that may not be able to handle all part configurations. Other practices such as stacking of overloaded containers can also increase the risk of part damage.
Are plant cleanliness, housekeeping, environmental
and working conditions conducive to control and
improved quality?
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The heat treater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, oil around quench tanks, inadequate plant lighting, smoke, etc.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
2.11
2.12
2.13
2.14
2.15
2.16
Section 3 - Equipment
3.1
3.2
Are parts free from contaminants that would be
detrimental to the heat treatment of the product?
Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat treatment. Parts shall be free from contaminants that are detrimental to subsequent processes or the product. Pre-wash (if applicable) and post-wash parameters shall be monitored and documented. Oils and other contaminants or residues can be difficult to remove once subjected to the heat treatment process. Review the chemical supplier’s recommendation for cleaning the system. Parts shall be free of rust, burrs, chips, detrimental amounts of drawing compound, cutting fluids, rust preventing oils, lubricants, etc., prior to heat treat. Note: Refer to the appropriate heat treater's requirements and specifications to determine acceptability. Refer to Process Table, Section 5.0, for frequency of checking washer solutions.
Is the quenching system monitored, documented, and
controlled?
The quenching system shall be monitored, documented, and controlled. The temperature, agitation, level, concentration (if applicable), time in the quenchant, and additions shall be controlled to the heat treater's specifications. Refer to Process Tables, Sections 3.0 and 5.0, for frequency of checks. Computer-monitoring equipment, with alarms and alarm logs, satisfy the verification requirement. Quench delay tolerance and alarm is required for furnaces with integral quench tanks. Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e.g., carburizing, carbonitriding, neutral hardening, solution treating and aging.
Is soluble oil or other rust preventive monitored and controlled if applicable?
Parts are often dipped in or sprayed with rust preventive solutions immediately after the heat treating process. Soluble oil solutions or other rust preventive solutions shall be monitored and controlled, if applicable. The heat treater shall have and maintain documented tolerances for the solutions. Refer to Process Tables, Section 5.0, for frequency of checks.
Are process control parameters monitored per frequencies specified in
Process Tables?
Process control parameters shall be monitored per frequencies specified in Process Tables. Refer to Process Tables, Section 3.0. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log. Management review is required per Question 1.9.
Are In-Process / Final Test Frequencies performed as
specified in Process Tables?
In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables, Section 4.0.
Is product test equipment verified?
Product test equipment shall be verified. Test equipment shall be verified/calibrated per applicable customer-specific standard or per an applicable consensus standard such as those published by ASTM, DIN, EN, ISO, JIS, NIST, SAE etc. Verification/calibration results shall be internally reviewed, approved, and documented. Refer to Process Tables, Section 1.0, for frequency of checks.
Do furnaces, generators, and quench systems have proper process control equipment?
The heat-treat furnaces, generators, and quench systems shall have proper process controls and related equipment. Examples include temperature, carbon potential/dew point, gas flows, quench monitoring system including agitation, temperature control and quenching oil analysis, etc. as listed in the applicable Process Tables, Section 1.0.
Are process equipment calibrations and/or verification certified, posted, and current?
The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables, Sections 1.0 and 2.0, for equipment calibration or certification time tables.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
3.3
3.4
3.5
3.6
3.7
Are thermocouples & protection tubes checked or
replaced per Process Tables?
The thermocouples and protection tubes shall be checked or replaced in compliance to a preventive maintenance schedule. Refer to the applicable Process Tables, Section 2.0.
Are temperature uniformity surveys performed per
requirements in Process Tables?
Temperature uniformity surveys shall be conducted per the requirements in the applicable Process Tables, Section 2.0. The frequency reductions allowed in AMS 2750D are not allowed under this document. Certain furnace designs, e.g., rotary retorts preclude direct temperature profiles. Alternate test methods per AMS 2750D 3.5.15 are acceptable for furnaces where temperature uniformity studies are not possible.
Is the variation of the furnace controlled thermocouple from
set point within the requirements in the Process
Table?
The variation between the furnace-control thermocouple and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.0. This does not apply to the first zone of a multi-zone continuous furnace.
Are the process & equipment alarm checks being tested
quarterly or after any repair or rebuild?
The heat treater shall have a list of heat treat process and equipment alarms. These alarms shall be independently tested quarterly at a minimum, and after any repair or rebuild. These checks shall be documented.
Are generators and furnace atmospheres continuously monitored, automatically
controlled, and documented?
Generator and furnace atmosphere carbon potential/dew point shall be continuously monitored, automatically controlled, and documented. This requirement is specific to Process Table 1, Sections 1.0 and 3.0, for carburizing, carbonitriding, and neutral hardening. Continuous monitoring and automatic control of the carbon potential/dew point is required for all generators and atmosphere furnaces except rotary retort and shaker furnaces that preclude in situ control and monitoring. For rotary retort and shaker furnaces, the method described in AMS 2750D 3.5.15..2 "Property Surveys" shall be used to ensure adequate control of the furnace atmosphere. If generators are not used, the flow rates of the supplied atmosphere gases shall be monitored and controlled. The assessor shall verify the effectiveness of the atmosphere control system per customer requirements, the heat treater’s control plan, and internal procedures.
The atmosphere control system shall maintain the atmosphere dew point/carbon potential set point within the parameters specified in the control plan or internal procedures. The heat treater shall have a back-up method of checking the carbon potential/dew point. Examples are dew point, electrical wire resistance, gas analysis, shim stock, carbon bar, etc. The automatic and continuous atmosphere control system shall consist of sensors such as oxygen probes or on-line Infrared (IR) gas analysis. See Process Table A, Sect. 3.0 for verification frequencies.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
3.8
3.9
3.10
3.11
3.12
When the back-up verification check of the atmosphere does not agree or correlate within
pre-established limits with the primary control method
(carbon potential/dew point reading), is correlation of the
carbon-bearing atmosphere to the primary control method re-
established?
This issue is specific to Process Table 1, carburizing, carbonitriding, and neutral hardening. When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), the heat treater shall resolve the out-of-limit discrepancy. The back-up atmosphere monitoring system reading and the automatically controlled atmosphere dew point/carbon potential reading shall be maintained within the correlation limits specified in the control plan or internal procedures. These range tolerances vary with the specific heat treat process and the equipment used. The heat treater shall make appropriate technical adjustments and corrections and then re-establish/demonstrate the correlation of the actual atmosphere carbon potential/dew point reading to the primary control and back-up atmosphere reading. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The back-up carbon potential/dew point reading shall be established using one or more of the following methods: • Carbon bar or slug• Shim stock• 3-gas analyzer• Dew point• Hot wire resistance
Are all ammonia lines equipped with quick
disconnects or a three valve fail safe vent system?
All ammonia lines to furnaces shall be equipped with quick disconnects or a three-valve fail-safe vent system. Normal valves may allow ammonia to leak through even when they are closed. This can be undesirable and detrimental in heat treat processes not specifying/requiring ammonia.• A quick disconnect shall be present in any ammonia line going to a furnace. This line shall be disconnected after carbonitriding (or any other process using ammonia) before another heat treating operation not specifying/using ammonia begins.• An alternative three-valve ammonia "fail-safe" vent system is permitted. See the definition “Three Valve Fail-Safe Vent” and diagram in the glossary.• Documentation shall show when ammonia lines are disconnected for non-ammonia bearing atmosphere processes.
For fasteners and small metal parts, is a minimum of 3 hours
allocated for an oxidizing burn-out prior to processing
product not requiring ammonia?
This is applicable to fasteners and small metal parts. The heat treater shall perform a minimum 3 hours oxidizing burn-out prior to processing product not requiring ammonia as an addition. Ammonia pick-up can be undesirable in parts and heat treat processes not specifying/requiring ammonia as an addition. Log book, data logger, or other records shall document the actual oxidizing burn-out time and that sufficient time has been allocated to remove ammonia from the furnace prior to processing parts in heat treat processes not specifying ammonia.
Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases?
All atmosphere furnaces and generators (output trim/adjustment gas) shall have flow scopes or flow meters for all gases. Flow scopes and meters shall be periodically serviced per the heat treater's preventive maintenance program. Cleaning and proper re-assembly procedures shall be documented.
For threaded fasteners, are all continuous belt furnaces equipped with sight glass
inspection ports and infrared pyrometers at discharge end of the hardening furnace?
Infrared temperature pyrometers are required at the exit end of continuous belt furnaces running threaded fasteners to monitor for under temperature parts. The temperature alarm shall be within 28C (50F) of the furnace set point temperature. Results shall be strip charted or continuously data logged. Infrared (IR) units shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule.
Special Process: Heat Treat System Assessment Index PageIndex PageCover PageCover Page
3.13
3.14
FOR INDUCTION HEAT TREATING
3.15
3.16
3.17
3.18 Is quench system automatic?
3.19
Is salt chemistry in the austenitizing salt bath
monitored?
Applicable to ferritic-nitrocarburizing, austempering, and neutral hardening in salt.The heat treater shall check the salt chemistry in the austentizing salt bath, or part decarburization, daily. Refer to the applicable Process Tables, Section 3.0, for frequency of checks.
Is the quenching medium analyzed?
The heat treater shall periodically have the quenching medium analyzed for specific quenching characteristics, e.g., cooling curve, water content, salt concentration, as specified in the applicable Process Tables, Section 5.0.• The quench media characteristic tolerances shall be specified by the quench medium supplier or the heat treater.• Analysis shall be reviewed for conformance by the heat treater. This review shall be documented.
Is the positioning of each part being controlled?
A method to detect proper part position, such as the use of proximity switches, optical sensors, mechanical probes, etc., is required for each part.
Does the heat treater control the energy or power for each part?
The heat treater shall control the energy or power for each part.• A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt, etc.) vs. time or distance (for scanning systems).• An energy monitor or equivalent is acceptable if approved by the authorized customer representative.
Does the supplier have a coil management system? Coil refers to the heating coil and the quench plenum.
The heat treater shall have a coil management system. Coil refers to the heating coil and the quench plenum.• Spare coils for each part shall be available on-site.• Coils shall conform to the approved original design.• Engineering change approval from the customer is required whenever the coil design is changed.
The quench system shall be an automatic operation. No manual quenching is allowed unless specifically approved by the authorized customer representative. Quenching shall be automatically initiated and controlled.
Does each lot of parts have first piece set-up?
The heat treater shall perform first piece set-up for each lot of parts
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Heat Treat Requirements:
Question # Job Audit Question
4.1
N/A
4.2 1.5 N/A
4.3
4.4
4.5 2.1
4.6
4.7
4.8 2.15
4.8.1 Requirement: (1)Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.2 Requirement: (2)Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.3 Requirement: (3)Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.4 Requirement: (4)Test Method:Test frequency or quantity:Selection of samples:Specification:
Operator or Inspector Responsibilities4.9
4.10
4.11
RelatedHTSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?
1.21.31.4
1.17
Does the heat treat facility have the customer specifications for the part?
Is a shop traveler created to meet customer requirements?
1.62.1
Is material identification (part numbers, lot numbers, heat numbers, contract numbers, etc.) maintained throughout the heat treat process?
2.22.32.4
Is there documented evidence of Receiving Inspection?
Are the Loading / Racking requirements identified?
1.62.72.9
Is the proper recipe or process specification (cycle times, temperature, atmosphere, etc.) used? Refer to Process Tables, Section 3.0, for specific parameters. List parameters that were verified in this audit in the spaces provided below.
1.51.62.1
2.142.15
What are the product inspection requirements?
Were appropriate process steps signed off?
1.42.22.3
2.14
Were all inspection steps, as documented in the control plan performed?
1.21.4
Were steps/operations performed that were not documented in the control plan?
1.21.41.6
Cover PageCover Page Index PageIndex Page
Section 4 - Job Audit
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Heat Treat Requirements:
Question # Job Audit QuestionRelated
HTSA Question #Customer or Internal
Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Cover PageCover Page Index PageIndex Page
4.12
4.13 1.11
4.14
4.15 1.17
4.16
Packaging Requirements
4.17 2.9
4.18 2.9
Shipping Requirements
4.19 Were the parts properly identified?
4.20
If additional steps were performed, were they authorized?
1.21.41.6
1.111.17
Does the governing specification allow reprocessing or rework?
If the order was certified, did the certification accurately reflect the process performed?
2.142.15
Was the certification signed by an authorized individual?
Are the parts and containers free of inappropriate objects or contamination?
2.62.11
Are packaging requirements identified?
Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?
2.32.9
Were the containers properly labeled?
2.32.9
Assessor(s) shall have the following specific experience to conduct the HEAT TREAT SYSTEM ASSESSMENT:
1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).
2 Assessor shall possess heat treating knowledge. Evidence shall include a minimum of 5years experience in heat treating or a combination of formal metallurgical education and heat treating experience totaling a minimum of 5 years.
3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.
Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Generators
1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTSA1.1 Yes Yes Yes
A1.2 Yes Yes
A1.3 1.18 Yes Yes Yes
A1.4 3.2 Yes Yes -----
A1.5 3.2 ----- ----- -----
A1.6 3.2 ----- ----- -----
A1.7 3.2 ----- ----- -----
A1.8 3.2 Yes Yes Yes
A1.9 2.16 ----- ----- -----
A1.10 2.16 ----- ----- -----
A1.11 3.2 ----- ----- -----
2.0 PYROMETRY
A2.1 Yes Yes Yes
A2.2 Yes Yes Yes
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
3.13.7
All furnaces, generators and quench systems shall have temperature indicating instruments.
3.13.7
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.
Yes
A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum.
Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.
Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.
Oxygen probe controllers shall be calibrated quarterly at a minimum.
All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.
Files shall be verified daily (or prior to use) with provers per SAE J864.
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
3.23.3
Thermocouples and calibration of thermocouples shall conform to AMS 2750D.
3.23.3
Instrument Calibration per AMS 2750D shall be quarterly at a minimum.
Frequency reductions per AMS 2750D are not allowed.
Cover PageCover Page Index PageIndex Page
Item # Category/Process Steps Generators
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
Cover PageCover Page Index PageIndex Page
A2.3 Yes Yes Yes
A2.4 3.4 Yes -----
A2.5 3.5 Yes -----
A2.6 3.5 Yes -----
A2.7 3.2 -----
3.0 PROCESS MONITOR FREQUENCIES
3.23.3
CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C). (1) The CTS shall be within an operating temperature range of +/- 5C (or +/-10F) of the CTTS. This check shall be performed monthly. (2) Within the operating temperature range the difference between the CTS and R-T/C readings shall be no more than +/- 1C (or +/-2F) as determined at the time of the most recent temperature uniformity survey. This check shall be performed weekly. Any actions to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.
Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum. Protection Tubes shall be visually checked at the same frequency as thermocouples.
Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.
Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).
Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.
Frequency reductions per AMS 2750D are not allowed.
Yes - In Qualified Work Zone
Recorded temperature(s) for austentizing processes shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Yes - In Qualified Work Zone
Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 6C (or +/- 10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Yes - In Qualified Work Zone
Infrared pyrometers shall be calibrated to a black body furnace annually.
Item # Category/Process Steps Generators
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
Cover PageCover Page Index PageIndex Page
A3.1 Monitor primary temperature control instrument(s). Each Shift
A3.2 Monitor generator atmospheres. ----- ----- Continuous
A3.3 Monitor primary furnace atmosphere control(s)**. -----
A3.4 Daily Daily Daily
A3.5 Daily Daily -----
A3.6 Quench Media Process Parameters
- Temperature -----
- Quench Level Daily Daily -----
- Agitation -----
A3.7 Monitor time in furnace, cycle time or belt speed. Each batch -----
A3.8 Monitor load size or fixturing or loading rate as applicable. Each batch -----
A3.9 Each batch -----
4.0 IN-PROCESS/FINAL TEST FREQUENCIES
A4.1 Microstructure Daily per furnace Daily per furnace -----
A4.2 Surface hardness Each batch Every 2 hours minimum -----
A4.3 Core hardness (when specified) Each batch Every 4 hours -----
A4.4 Case depth (when specified) Each batch Every 4 hours -----
5.0 QUENCHANT AND SOLUTION TEST FREQUENCIESA5.1 Polymer Quench Media
- Concentration Daily Daily -----
1.42.14
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
1.42.143.7
1.42.143.7
Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
1.42.143.7
Verify primary atmosphere control method by back-up method**.
1.42.143.13
For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.
1.42.12
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
- Daily visual check is required.
- Monitor each load in the absence of an alarm system.
- Daily visual check is required.
- Monitor every 2 hours in the absence of an alarm system.
1.42.14
Twice/shift & after any change in the belt speed.
1.42.7
Twice/shift & after any change in loading rate.
1.42.12
Quench Delay Time -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.
Each basket for pusher-type continuous furnaces. Not applicable for belt furnaces.
1.42.15
1.42.15
1.42.15
1.42.15
2.123.14
Item # Category/Process Steps Generators
PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
Cover PageCover Page Index PageIndex Page
A5.1
Every six months Every six months -----
A5.2 Water Quench Media- Suspended solids Every six months Every six months -----
A5.3 Salt Quench Media- Analysis & Contaminants Every six months Every six months -----
A5.4 Brine or Caustic Quench Media
Daily Daily -----
- Suspended solids Every six months Every six months -----A5.5 Oil Quench Media
Quarterly Quarterly -----
A5.6 2.13 Rust Preventive - Soluble Oil
- Concentration 2x / week 2x / week -----A5.7 2.11 Washers
- Concentration of cleaner Daily Daily -----Each shift Each shift -----
2.123.14
- Quenchability Check; e.g., cooling curve, viscosity, or titration
2.123.14
2.123.14
2.123.14 - Concentration and/or Specific
Gravity.
2.123.14 - Water content, suspended solids,
viscosity, cooling curve, total acid, and flash point.
- Temperature of solution (required if temperature is specified to be above ambient temperature).
Item # Category/Process Steps Generators Salt Bath
1.0
B1.1 Yes Yes Yes Yes
B1.2 Yes Yes
B1.3 1.18 Yes Yes Yes -----
B1.4 ----- ----- ----- Yes
B1.5 3.2 Yes Yes ----- -----
B1.6 3.2 ----- ----- ----- -----
B1.7 2.16 ----- ----- ----- -----
B1.8 2.16 ----- ----- ----- -----
B1.9 3.2 ----- ----- ----- -----
2.0 PYROMETRY B2.1 Yes Yes Yes Yes
B2.2 Yes Yes Yes Yes
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Furnace
ContinuousFurnace*
PROCESS AND TEST EQUIPMENT REQUIREMENTS
3.13.7
All furnaces, generators and quench systems shall have temperature indicating instruments.
3.13.7
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.
Yes Yes - For
temperature only
A program for furnace and generator burnout is required. Not required for retort gas nitriding.
3.123.13
For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.
All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.
Files shall be verified daily (or prior to use) with provers per SAE J864.
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
3.23.3
Thermocouples and calibration of thermocouples shall conform to AMS 2750D.
3.23.3
Instrument Calibration per AMS 2750D shall be quarterly at a minimum.
Frequency reductions per AMS 2750D are not allowed.
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Generators Salt Bath
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Furnace
ContinuousFurnace*
Index PageIndex PageCover PageCover Page
B2.3 Yes Yes Yes Yes
B2.4 3.4 Yes ----- Yes
3.23.3
CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.
(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.
Any actions to correct a failing reading or validate a test result shall be documented.
Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.
Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum.
Protection Tubes shall be visually checked at same frequency as thermocouples.
Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.
Temperature uniformity tolerance shall be +/- 9 C (15 F).
Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.
Frequency reductions per AMS 2750D are not allowed.
Yes - In Qualified Work Zone
Item # Category/Process Steps Generators Salt Bath
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Furnace
ContinuousFurnace*
Index PageIndex PageCover PageCover Page
B2.5 3.5 Yes ----- Yes
B2.6 3.2
3.0 PROCESS MONITOR FREQUENCIESB3.1 Monitor primary temperature control instrument(s). Each Shift
B3.2 Monitor generator atmospheres, if applicable. ----- ----- Continuous -----
B3.3 Monitor primary furnace atmosphere control(s). ----- Daily
B3.4 Every 4 hours Daily N/A
B3.5 Gas ratios for ferritic nitrocarburizing shall be checked. Each batch
B3.6 ----- ----- ----- Daily
B3.7 Quench Media Process Parameters
Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Yes - In Qualified Work Zone
Infrared pyrometers shall be calibrated to a black body furnace annually .
1.42.14
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
Every 2 hours & after any change
1.42.143.7
1.42.143.7
Each batch (rotary furnaces only) or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement
1.43.7
Dissociation of ammonia shall be checked in gas nitriding.
Each batch and every 4 hours minimum
1.43.7
Every 2 hours minimum
1.42.143.13
Check salt chemistry (soluble oxides) in salt baths used for austenitizing, or decarburization on the parts.
1.42.12
Item # Category/Process Steps Generators Salt Bath
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Furnace
ContinuousFurnace*
Index PageIndex PageCover PageCover Page
B3.7
- Temperature -----
- Quench Level Daily Daily ----- Daily- Agitation ----- Daily
B3.8 Monitor time in furnace, cycle time or belt speed. Each batch ----- Each batch
B3.9 Each batch ----- Each batch
B3.10 Each batch ----- Each batch
4.0 IN-PROCESS/FINAL TEST FREQUENCIES B4.1 Microstructure Daily per furnace -----
B4.2 Surface hardness Each batch ----- Each batch
B4.3 Core hardness (when specified) Each batch Every 4 hours ----- Each batch
B4.4 Case depth (when specified) Each batch Every 4 hours ----- Each batch
5.0
Quench Media Controls If ApplicableB5.1 Polymer Quench Media
- Concentration Daily Daily ----- -----Every six months ----- -----
B5.2 Water Quench Media- Suspended solids Every six months ----- -----
B5.3 Salt Quench Media- Analysis & Contaminants Every six months -----
B5.4 Brine or Caustic Quench Media
1.42.12 Each batch or
continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
- Daily - Monitor each load in the absence of an alarm system.
- Daily - Monitor every 2 hours in the absence of an alarm system.
1.42.14
Twice/shift & after any change in the belt speed.
1.42.7
Monitor load size or fixturing or loading rate as applicable.
Twice/shift & after any change in loading rate.
1.42.12
Quench Delay Time if applicable -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.
Each basket if applicable.
1.42.15
Daily per furnace
Daily per furnace
1.42.15
Every 2 hours minimum
1.42.15
1.42.15
QUENCHANT AND SOLUTION TEST FREQUENCIES
2.123.14
- Quenchability Check; e.g., cooling curve, viscosity, or titration.
Every six months
2.123.14 Every six
months
2.123.14 Every six
monthsEvery six months
2.123.14
Item # Category/Process Steps Generators Salt Bath
PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Furnace
ContinuousFurnace*
Index PageIndex PageCover PageCover Page
B5.4 Daily Daily ----- -----
- Suspended solids Every six months ----- -----
B5.5 Oil Quench MediaQuarterly Quarterly ----- -----
B5.6 2.13 Rust Preventive - Soluble Oil- Concentration 2x / week 2x / week ----- 2x / week
B5.7 2.11 Washers- Concentration of cleaner Daily Daily ----- Daily
Each shift Each shift ----- Each shift
2.123.14 - Concentration and/or Specific
Gravity
Every six months
2.123.14 - Water content, suspended solids,
viscosity, cooling curve, total acid, and flash point.
- Temperature of solution (required if temperature is specified to be above ambient temperature).
Item # Category/Process Steps
1.0
C1.1 Yes Yes Yes
C1.2 Yes Yes
C1.3 2.16 ----- ----- -----
C1.4 3.2 Yes Yes Yes
C1.5 3.2 ----- ----- -----
2.0 PYROMETRY C2.1 Yes Yes Yes
C2.2 Yes Yes Yes
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Solution Treating and Aging Furnaces
Continuous Solution Treating and Aging
Furnaces
Annealing Furnace
PROCESS AND TEST EQUIPMENT REQUIREMENTS
3.13.7
All furnaces and quench systems shall have temperature indicating instruments.
3.13.7
Continuous strip charts and/or data loggers are required for temperature sensors.
Yes
All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
3.23.3
Thermocouples and calibration of thermocouples shall conform to AMS 2750D.
3.23.3
Instrument Calibration per AMS 2750D shall be quarterly at a minimum.
Frequency reductions per AMS 2750D are not allowed.
Cover PageCover Page Index PageIndex Page
Item # Category/Process Steps
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Solution Treating and Aging Furnaces
Continuous Solution Treating and Aging
Furnaces
Annealing Furnace
Cover PageCover Page Index PageIndex Page
C2.3 Yes Yes Yes
C2.4 3.4 Yes Yes
3.23.3
CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.
(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the last temperature uniformity survey; this checked shall be performed weekly.
Any actions to correct a failing reading or validate a test result shall be documented.
Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.
Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.
Protection Tubes shall be visually checked at same frequency as thermocouples.
Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be quarterly and after major rebuild.
Temperature uniformity tolerance for solution treating and aging furnaces shall be +/- 6 C (or +/- 10 F). Temperature uniformity tolerance for annealing furnaces shall be +/- 14 C (or +/- 25 F).
Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.
Frequency reductions per AMS 2750D are not allowed.
Yes - In Qualified Work Zone
Item # Category/Process Steps
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Solution Treating and Aging Furnaces
Continuous Solution Treating and Aging
Furnaces
Annealing Furnace
Cover PageCover Page Index PageIndex Page
C2.5 3.5 Yes -----
C2.6 3.5 ----- ----- Yes
C2.7 3.2
3.0 PROCESS MONITOR FREQUENCIESC3.1 Monitor primary temperature control instrument(s).
C3.2 Quench Media Process Parameters-----
- Quench Level Daily Daily ------ Agitation -----
C3.3 Monitor process cycle time Each batch Each batch
C3.4 Monitor load size or fixturing as applicable. Each batch Each batch
C3.5 Each batch Each load -----
4.0 IN-PROCESS/FINAL TEST FREQUENCIES
Recorded temperature(s) shall be controlled within +/- 6C (or +/- 10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Yes - In Qualified Work Zone
Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Infrared pyrometers shall be calibrated to a black body furnace annually.
1.42.14
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
1.42.12 - Heat treater shall specify temperature range based
on product form and material. Temperature shall be monitored as noted.
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
- Daily visual check is required.
- Monitor each load in the absence of an alarm system.
- Daily visual check is required.
- Monitor every 2 hours in the absence of an alarm system.
1.42.14
Twice/shift & after any change in the indexing speed.
1.42.7
Twice/shift & after any change in loading rate.
1.42.12
Quench Delay Time -Quench delay time shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.
Item # Category/Process Steps
PROCESS TABLE C - Aluminum Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".
Related HTSA
Question #
Batch Solution Treating and Aging Furnaces
Continuous Solution Treating and Aging
Furnaces
Annealing Furnace
Cover PageCover Page Index PageIndex Page
C4.1 Hardness or tensile testing (post aging). Each batch Every 4 hours
5.0
C5.1 Polymer Quench Media- Concentration Daily Daily ------ Suspended solids Every six months Every six months -----
Every six months Every six months -----
C5.2 Water Quench Media- Suspended solids Every six months Every six months -----
C5.3 2.11 Washers- Concentration of cleaner Daily Daily Daily
Each shift Each shift Each shift
1.42.15
Each batch or every 4 hours for continuous furnaces
QUENCHANT AND SOLUTION TEST FREQUENCIES
2.123.14
- Quenchability Check; e.g., cooling curve, viscosity, or titration.
2.123.14
- Temperature of solution (required if temperature is specified to be above ambient temperature).
Item # Category/Process Steps Per Coil
1.0
D1.1 --- Per customer requirementD1.2 2.16 -----
D1.3 2.16 -----
D1.4 3.2 -----
2.0 PYROMETRY D2.1 3.2 -----
3.0 PROCESS MONITORING FREQUENCIES
D3.1 Quench Media Process Parameters
- Temperature
- Quench Level Daily
- Quench Pressure and Flow
PROCESS TABLE D - Induction Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".
Related HTSA Question #
PROCESS AND TEST EQUIPMENT REQUIREMENTS
All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.
Files shall be verified daily (or prior to use) with provers per SAE J864.
Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified each shift (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.
Infrared pyrometers shall be calibrated to a black body furnace annually.
All process parameters shall be checked the beginning of every shift, tool change, or any equipment repair. In absence of process parameter alarms, also check process parameters at end of shift or lot (whichever is the greater frequency).
1.42.12 Alarm system for high and low
temperature is required.
- Quench pressure and flow may checked at manifold. Quench flow shall be checked visually at each coil.- In the absence of an alarm system, monitor every 2 hours or after any change.
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Per Coil
PROCESS TABLE D - Induction Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".
Related HTSA Question #
Index PageIndex PageCover PageCover Page
D3.2 Monitor cycle time
D3.3
4.0
D4.4 Induction pattern length
D4.5 Total or Effective Case depth
D4.6 Surface hardness
D4.7 Core hardness (when specified)
1.42.14
Check cycle time at start up and after any process change.
1.42.143.16
Monitor: 1) Volts or Amps, and2) KilowattsUse of an energy monitor or signature monitor satisfies 1) and 2).
- This requirement applies to each power supply (not per coil). - In the absence of an alarm system, monitor every 2 hours or after any change.
IN-PROCESS/FINAL TEST FREQUENCIES
Production Setup or Coil Change - Per Coil(1st Piece Inspection)
1.42.15
1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)
1.42.15
1 part at start-up, end of production run, and 1 part per 8 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)
1.42.15
1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)
1.42.15
1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)
Item # Category/Process Steps Per Coil
PROCESS TABLE D - Induction Heat Treating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".
Related HTSA Question #
Index PageIndex PageCover PageCover Page
D4.8 Microstructure
5.0
Quench Media Controls If ApplicableD5.1 Polymer Quench Media
- Concentration Once per dayMonthly
D5.2 Water Quench Media- Suspended solids Quarterly
D5.3 Brine or Caustic Quench MediaMonthly
- Suspended solids QuarterlyD5.4 2.13 Rust Preventive - Soluble Oil
- Concentration 2x / weekD5.5 2.11 Washers
- Concentration of cleaner DailyEach shift
1.42.15
1 part at start-up, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)
QUENCHANT AND SOLUTION TEST FREQUENCIES
2.123.14
- Quenchability Check; e.g., cooling curve, viscosity, or titration
2.123.14
2.123.14 - Concentration and/or Specific
Gravity
- Temperature of solution (required if temperature is specified to be above ambient temperature).
Item # Category/Process Steps Generators
1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS
E1.1 Yes Yes Yes
E1.2 Yes Yes
E1.3 3.2 Yes Yes -----
E1.4 3.2 ----- ----- -----
E1.5 3.2 ----- ----- -----
E1.6 3.2 ----- ----- -----
E1.7 3.2 Yes Yes Yes
E1.8 2.16 ----- ----- -----
2.0 PYROMETRY
E2.1 Yes Yes Yes
E2.2 Yes Yes Yes
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
3.13.7
All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments.
3.13.7
Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.
Yes
Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.
Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.
Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use. This is applicable when used in controlling carbon-bearing atmospheres.
Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.
Oxygen probe controllers shall be calibrated quarterly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.
All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.
3.23.3
Thermocouples and calibration of thermocouples shall conform to AMS 2750D.
3.23.3
Instrument Calibration per AMS 2750D shall be quarterly at a minimum.
Frequency reductions per AMS 2750D are not allowed.
Cover PageCover Page Index PageIndex Page
Item # Category/Process Steps Generators
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
Cover PageCover Page Index PageIndex Page
E2.3 Yes Yes Yes
E2.4 3.4 Yes -----
E2.5 3.5 Yes -----
3.0 PROCESS MONITOR FREQUENCIES
3.23.3
CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).
(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.
(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.
Any actions to correct a failing reading or validate a test result shall be documented.
Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.
Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.
Protection Tubes shall be visually checked at same frequency as thermocouples.
Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.
Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).
Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.
Frequency reductions per AMS 2750D are not allowed.
Yes - In Qualified Work Zone
Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).
Yes - In Qualified Work Zone
Item # Category/Process Steps Generators
PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.
* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".
Related HTSA Question #
Batch Furnace
ContinuousFurnace *
Cover PageCover Page Index PageIndex Page
E3.1 Monitor primary temperature control instrument(s). Each Shift
E3.2 Monitor generator atmospheres ----- ----- Continuous
E3.3 Monitor primary furnace atmosphere control(s)**. -----
E3.4 Daily Daily Daily
E3.5 Daily Daily -----
E3.6 Monitor time in furnace, cycle time or belt speed. Each batch -----
E3.7 Each batch -----
4.0 IN-PROCESS/FINAL TEST FREQUENCIES
E4.1 Microstructure (when specified) Daily per furnace Daily per furnace -----
E4.2 Surface hardness (when specified) Each batch Every 2 hours minimum -----
E4.3 Core hardness (when specified) Each batch Every 4 hours -----
5.0 SOLUTION TEST FREQUENCIES
E5.1 2.13 Rust Preventive - Soluble Oil
- Concentration 2x / week 2x / week -----
E5.2 2.11 Washers
- Concentration of cleaner Daily Daily -----
Each shift Each shift -----
1.42.14
Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
1.42.143.7
1.42.143.7
Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.
1.42.143.7
Verify primary atmosphere control method by back-up method**.
1.42.143.13
For salt baths: check salt chemistry (soluble oxides) in salt baths or decarburization on the parts.
1.42.14
Twice/shift & after any change in the belt speed.
1.42.7
Monitor load size or fixturing or loading rate as applicable.
Twice/shift & after any change in loading rate.
1.42.15
1.42.15
1.42.15
- Temperature of solution (required if temperature is specified to be above ambient temperature).
CQI-11 PLATING SYSTEM ASSESSMENT
Instructions for completing the Cover Sheet
1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physicallocations in the same general area. If there is a separate management team (Quality Manager andPlating Specialist) or different management system, then these locations shall be considered asseparate facilities.
2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
4 Fax number: The fax number of the facility.
5 Number of Plating Employees at this Facility: The number of employees, salaried and hourly, associated with the plating operation at this facility.
6 Captive Plater (Y/N): Enter "Y" if this facility Plates components for their own company. Enter"N" if the company does not Plate any components for their own company.
7 Commercial Plater (Y/N): Enter "Y" if this facility Plates components for companies other thantheir own company. Enter "N" if this facility does not Plate any components for other companies.
8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.Example: May 3 -- 4, 2006.
9 Date of Previous Assessment: List the date of the previous CQI-11 Special Process: PlatingSystem Assessment of this facility.
10 Type(s) of Plating at this Facility: Place a checkmark to designate the Plating process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the PlatingSystem Assessment.
11 Current Quality Certification(s): the plater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the plater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 5, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the plater's organization.
14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
Cover PageCover Page Index PageIndex Page
Special Process: Plating System Assessment
Facility Name:Address:
Phone Number: Type(s) of Plating Processing at this Facility:Fax Number: Process Table A
ZincNumber of Plating Employees at this Facility: Zinc Alloy Plating
Captive Plater (Y/N): Process Table BCommercial Plater (Y/N):
Date of Assessment: Process Table C
Date of Previous Assessment:Process Table DDecorative Plating
Process Table EMechanical Plating
Process Table FEquipmentProcess Equipment
Current Quality Certification(s):
Date of Re-assessment (if necessary):
Personnel Contacted:Name: Title: Phone: Email;
0 00 00 00 0
Auditors/Assessors:Name: Company: Phone: Email:
0000
Number of "Not Satisfactory" Findings:
Number of "Needs Immediate Action" Findings:
Number of "Fail" Findings in the Job Audit(s):
Surface Conditioning of Metals for Decorative Plating
Surface Conditioning of ABS & PCABS Plastics for Decorative Plating
Cover PageCover Page Index PageIndex Page
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.1
1.2
1.3
1.4
Question Number
Not Satisfactory
Needs Immediate Action
Is there a dedicated and qualified plating person on-site?
To ensure readily available expertise, there shall be a dedicated and qualified plating person on the site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the postition including chemical and plating knowledge. The qualifications shall include a minimum of 5 years experience in plating and surface finishing or a combination of formal chemistry/chemical engineering education and plating experience totaling a minimum of 5 years.
Does the plater perform advanced quality planning?
The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The plater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Are plater FMEA's up to date and reflecting current processing?
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEAs are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key plating process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
Are finish process control plans up to date and reflecting current processing?
The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key plating process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEAs. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and Frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.
Index PageIndex PageCover PageCover Page
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate Action
Index PageIndex PageCover PageCover Page
1.5
1.6
1.7
Are all plating related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.
To ensure all customer requirements are both understood and satisfied, the organization shall have all related plating and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and specifications and changes based on customer-required schedule. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.
Is there a written process specification for all active processes?
The plater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, rectifier settings, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.
Has a valid product capability study been performed initially and after process change?
To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all plating processes per line as defined in scope of work and in accordance with customer requirements. Capability study techniques shall be appropriate for the plating product characteristics, e.g. plate thickness, corrosion resistance, etc.. Any specific customer requirements shall be met. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate Action
Index PageIndex PageCover PageCover Page
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
Does the plater collect and analyze data over time, and react to this data?
The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis.
Does management review and verify bake oven logs for parts requiring hydrogen embrittlement relief every 24 hours?
Management shall review the oven monitoring systems/logs at intervals not to exceed 24 hours or prior to parts being released for shipment. The plater shall have reaction plans for non-conformances to process requirements. This is to contain, at minimum, requirements for quarantining material and notifying customer.
Are internal assessments being completed on an annual basis, at a minimum, incorporating AIAG PSA?
The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG PSA. Concerns shall be addressed in a timely manner.
Is there a system in place toauthorize reprocessing and is it documented?
The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual. The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. All reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary plating modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.
Does the Quality Department review, address, and document customer and internal concerns?
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.
Is there a continual improvement plan applicable to each process defined in the scope of the assessment?
The plater shall define a process for continual improvement for each plating process identified in the scope of the PSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.
Does the Quality Manager or designee authorize the disposition of material from quarantine status?
The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.
Are there procedures or work instructions available to plating presonnel that define the plating process?
There shall be procedures and work instructions available to plating personnel covering the plating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate Action
Index PageIndex PageCover PageCover Page
1.16
1.17
1.18
1.19
Section 2 - Floor and Material Handling Responsibility
2.1
2.2
2.3
Is management providing employee training for plating?
The organization shall provide employee training for all plating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.
Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?
The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.
Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program?
The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner. Company data, e.g., downtime, quality rejects, first time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.
Has the plater developed a critical spare part list and are the parts available to minimize production disruptions?
The plater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.
Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?
Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.
Is product clearly identified and staged throughout the plating process?
Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the plating process. Non-plated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.
Is lot traceability and integrity maintained throughout all processes?
Out-going lot(s) shall be traceable to the incoming lot(s). The descipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate Action
Index PageIndex PageCover PageCover Page
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
Are procedures adequate to prevent movement of non-conforming product into the production system?
The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material.
Is there a system to identify trap points in the entire plating process to reduce risk of mixed parts (inappropriate, unfinished, or improperly plated parts)?
The plater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.
Are containers free of innappropriate material?
Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming plating parts or inappropriate material contaminate the finished lot.
Is part loading specified, documented and controlled?
Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.
Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?
Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.
Is the handling, storage and packaging adequate to preserve product quality?
The plater's loading/unloading systems, in process handling and shipping process shall be assessed for risk of part damage or other quailty concerns.
Are plant cleanliness, housekeeping and environmental and working conditions conducive to control and improved quality?
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quailty. The plater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes etc.
Are process control parameters monitored per frequencies specified in Process Tables?
Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.
Are out of control/specification parameters reviewed and reacted to?
Are there documented reaction plans to both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?
Are In-Process / Final Test Frequencies performed as specified in Process Tables?
In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables.
Special Process: Plating Process Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate Action
Index PageIndex PageCover PageCover Page
2.14Is product test equipment verified?
Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.
Refer to Process Tables for frequency of checks.
Section 3 - Zinc/ Zinc Alloy Plating Equipment
Assessment
Question Objective Evidence N/A Satisfactory Not Satisfactory
3.1
3.2
3.3
3.4 Are rectifiers maintained?
3.5
3.6
Question Number
Requirements and GuidanceNeeds Immediate
Action
Does plating line have proper process control equipment?
Refer to Process Table F for equipment requirements.
Are process and testing equipment calibrations and/or verification certified, posted, and current?
A system shall be used by the plating facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.
Are barrels, racks, and baskets maintained?
Supplier shall have preventative maintenance system that is documented and implemented.
Supplier shall have preventative maintenance system that is documented and implemented.
For hydrogen embrittlement relief ovens, are temperature uniformity surveys performed yearly?
Uniformity survey must show that ovens were tested both empty and with a dense load. Parts must come up to temperature within one hour of entering oven and meet temperature tolerance specified by customer.
For hydrogen embrittlement relief ovens, are thermocouples checked and/or replaced quarterly?
Supplier shall have preventative maintenance system that is documented and implemented.
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Section 4 - Decorative (Cu, Ni, Cr) Plating Equipment
Question Objective Evidence
Assessment
N/A Satisfactory
4.1
4.2
4.3 Are racks maintained?
4.4 Are rectifiers maintained?
4.5 Are filters maintained?
4.6
4.7
4.8
Question Number
Requirements and Guidance Not Satisfactory
Needs Immediate
Action
Does plating line have proper process control equipment?
Refer to Process Table F for equipment requirements.
Are process and testing equipment calibrations and/or verification certified, posted, and current?
A system shall be used by the plating facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented. Refer to Process Table F, for equipment certification time table
Supplier shall have preventative maintenance system that is documented and implemented.
Supplier shall have preventative maintenance system that is documented and implemented.
Supplier shall have preventative maintenance system that is documented and implemented.
Is all other applicable equipment maintained?
Supplier shall have preventative maintenance system that is documented and implemented.
For all thermocouples/ thermometers are they checked and/or replaced?
Supplier shall have preventative maintenance system that is documented and implemented.
Are the process and equipment alarm checks being tested?
Checks shall be documented. Each alarm shall be reviewed independently for functionality if applicable. Plater shall have a list of alarms relevant to process.
Index PageIndex PageCover PageCover Page
Section 5 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Plating Requirements:
Job Audit Question
5.1
N/A
5.2 1.5 N/A
5.3
5.4
5.5 2.1
5.6
5.7
5.8 2.13
5.8.1 Requirement: Plate ThicknessTest Method:Test frequency or quantity:Selection of samples:Specification:
5.8.2
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.3
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.4 Requirement: Adhesion TestTest Method:Test frequency or quantity:
Question #
RelatedPSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?
1.21.31.4
1.17
Does the plater have the proper customer specifications for the part?
Is a shop traveler created to meet customer requirements?
1.62.1
Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the plating process?
2.22.32.4
Is there documented evidence of Receiving Inspection?
Are the Loading / Racking requirements identified?
1.62.72.9
Is the proper procedure or process specification used? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.
1.51.62.1
2.112.13
What are the product inspection requirements?
Each part may have one or more requirements determined by the plating specification. Parts must meet each requirement. List each requirement below and validate.
Requirement: Corrosion Resistance
Requirement: Hydrogen Embrittlement Relief (if Applicable)
Cover PageCover Page Index PageIndex Page
Section 5 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Plating Requirements:
Job Audit QuestionQuestion #
RelatedPSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Cover PageCover Page Index PageIndex Page
Selection of samples:Specification:
5.8.5 Requirement: Alloy (if Applicable)
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.6
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.7
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.8
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.9
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.10
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.11
Test Method:Test frequency or quantity:Selection of samples:Specification:
5.8.12
Test Method:Test frequency or quantity:Selection of samples:Specification:
Operator or Inspector Responsibilities5.9
5.10
Requirement: Torque Tension (if Applicable)
Requirement: Appearance (Decorative)
Requirement: S.T.E.P. (Decorative)
Requirement: Pore Count/Size (Decorative)
Requirement: Ductility by foil (Decorative)
Requirement: Internal Stress (Decorative)
Requirement:Thermal Cycle (Decorative Plastic)
Were appropriate process steps signed off?
1.42.22.3
2.11
Were all inspection steps, as documented in the control plan performed?
1.21.4
Section 5 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Plating Requirements:
Job Audit QuestionQuestion #
RelatedPSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
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5.11
5.12
5.13
5.14 1.17
5.15 2.6
Packaging Requirements5.16 2.9
5.17 2.9
Shipping Requirements5.18 2.3
5.19
Were steps/operations performed that were not documented in the control plan?
1.21.41.6
If additional steps were performed, were they authorized?
1.21.41.6
1.111.17
If the order was certified, did the certification accurately reflect the process performed?
2.112.13
Was the certification signed by an authorized individual?
Are the parts and containers free of foreign objects or contamination?
Are packaging requirements identified?
Are parts packaged to minimize mixed parts (parts packed over height of container)?
Were the parts properly identified?
Were the containers properly labeled?
2.32.9
Assessor(s) shall have the following specific experience to conduct the PLATING SYSTEM ASSESSMENT:
1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).
2 Assessor shall possess plating knowledge. Evidence shall include a minimum of 5 years experience in plating and surface finishing or a combination of formal chemsitry/chemical engineering education and plating experience totaling a minimum of 5 years.
3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.
Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.
Index PageIndex PageCover PageCover Page
ITEM # Category/Process Steps Control Monitoring
1.0 Metal CleaningType:Size,volume:Proprietary name:Chemical supplier:
A1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/DayA1.3 1.4; 2.11; 2.13 Time Per Tech Data Sheet Per Process SheetA1.4 Agitation Per Tech Data Sheet Per Process SheetA1.5 1.4; 2.11; 2.13 Current/Voltage (As applicable) Automatic 1/ShiftA1.6 Solution Level Automatic or Manual 1/ShiftA1.7 Rinse Process Sheet 1/Shift2.0 Acid
Type:Size,volume:Proprietary name:Chemical supplier:
A2.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/ShiftA2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftA2.3 1.4; 2.11; 2.13 Automatic Continuous
A2.4 Inhibitor Per Tech Data Sheet N/AA2.5 Solution Level Automatic or Manual 1/ShiftA2.6 Rinse Process Sheet 1/Shift3.0 Acid Plating Bath
Type:Size,volume:Proprietary name:Chemical supplier:
A3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA3.2 1.4; 2.11; 2.13 Time Automatic 1/ShiftA3.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/ShiftA3.4 Chloride Concentration Manual 1/DayA3.5 pH Automatic or Manual 1/ShiftA3.6 Plating Test Cell (Hull) Manual 1/DayA3.7 Metal Concentration(s) Automatic or Manual 1/DayA3.8 Buffer (Ammonia / Boric Acid per TDS) Manual 1/DayA3.9 Filtration Continuous 1/Shift
A3.10 Agitation (Rack only - others optional) Continuous 1/ShiftA3.11 Rinse Per Process Sheet 1/Shift
4.0 Alkaline Plating BathType:Size,volume:Proprietary name:
PROCESS TABLE A - Zinc - Zinc Alloy Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Time (Less than 10 Minutes or Customer Specific)
Cover PageCover Page Index PageIndex Page
ITEM # Category/Process Steps Control Monitoring
PROCESS TABLE A - Zinc - Zinc Alloy Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Cover PageCover Page Index PageIndex Page
Chemical supplier:A4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftA4.2 1.4; 2.11; 2.13 Time Automatic 1/ShiftA4.3 1.4; 2.11; 2.13 Current/Voltage Automatic 1/ShiftA4.4 Caustic Concentration Manual 1/DayA4.5 Plating Test Cell (Hull) Manual 1/DayA4.6 Metal Concentration(s) Automatic or Manual 1/DayA4.7 Filtration Continuous 1/ShiftA4.8 Rinse Per Process Sheet 1/Shift5.0 Hydrogen Embrittlement Relief
3.6 Oven Type:3.6 Oven Temperature:
6.0 PassivatesType:Size,volume:Proprietary name:Chemical supplier:
A6.1 Acid Activation Per Control Plan N/AA6.1.1 - Concentration Automatic or Manual 1/ShiftA6.1.2 1.4; 2.11; 2.13 - Time Automatic or Manual 1/ShiftA6.2 Passivate Per Control Plan N/A
A6.2.1 - Concentration Automatic or Manual 1/ShiftA6.2.2 1.4; 2.11; 2.13 - Temperature Automatic or Manual 1/ShiftA6.2.3 1.4; 2.11; 2.13 - Time Automatic or Manual 1/ShiftA6.2.4 - pH Automatic or Manual 1/ShiftA6.2.5 - Agitation Automatic or Manual 1/ShiftA6.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/weekA6.3 Rinse Per Process Sheet 1/ShiftA6.4 Dry Per Tech Data Sheet Per Process Sheet
7.0
A7.1 Concentration Automatic or Manual
A7.2 1.4; 2.11; 2.13 Solution Temperature Automatic
A7.3 1.4; 2.11; 2.13 Time Automatic or Manual
A7.4 pH Automatic or Manual
A7.5 Drying Temperature Automatic
A7.6 Spin Speed Automatic
Supplemental Treatments - Sealers and Torque Tension Modifiers
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
ITEM # Category/Process Steps Control Monitoring
PROCESS TABLE A - Zinc - Zinc Alloy Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Cover PageCover Page Index PageIndex Page
A7.7 Agitation Automatic or Manual Per Control Plan and TDS
ITEM # Category/Process Steps Control Monitoring
1.0 Polishing and BuffingB1.1 ManualB1.2 AutomaticB1.3 SteelB1.4 Stainless SteelB1.5 AluminumB1.6 Zinc diecast2.0 Metal Cleaning
Type:Size,volume:Proprietary name:Chemical supplier:
B2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftB2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftB2.3 1.4; 2.11; 2.13 Time Per TDS Per process sheetB2.4 Agitation - Optional Per TDS Per process sheetB2.5 4.4 Current/Voltage (As applicable) Automatic 1/ShiftB2.6 Solution Level Automatic or Manual 1/ShiftB2.7 Rinse Process Sheet 1/Shift3.0 Pretreatment
B3.1 Strike (As applicable) N/A N/AB3.1.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftB3.1.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftB3.1.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetB3.1.4 - Agitation - Optional Per TDS Per process sheetB3.1.5 4.4 - Current/Voltage (if applicable) Automatic 1/ShiftB3.1.6 - Solution Level Automatic or Manual 1/ShiftB3.1.7 - Rinse Process Sheet 1/ShiftB3.2 Zincate (Aluminum Only) N/A N/A
B3.2.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftB3.2.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftB3.2.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetB3.2.4 - Agitation - Optional Per TDS Per process sheetB3.2.5 - Solution Level Automatic or Manual 1/ShiftB3.2.6 - Dump Schedule Per TDS Per process sheetB3.2.7 Rinse Process Sheet 1/Shift
4.0 AcidType:Size,volume:Proprietary name:Chemical supplier:
B4.1 1.4; 2.11; 2.13 Temperature - Optional Automatic 1/ShiftB4.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftB4.3 1.4; 2.11; 2.13 Time (Per Specification) Automatic Continuous
PROCESS TABLE B - Surface Conditioning of Metals for Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
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ITEM # Category/Process Steps Control Monitoring
PROCESS TABLE B - Surface Conditioning of Metals for Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Index PageIndex PageCover PageCover Page
B4.4 Solution Level Automatic or Manual 1/ShiftB4.5 Rinse Process Sheet 1/Shift
(Proceed to Process Table D - Decorative Plating)
ITEM # Category/Process Steps Control Monitoring
1.0 Cleaning and Pre-Etch (If Applicable)Type:Size,volume:Proprietary name:Chemical supplier:
C1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC1.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC1.4 Agitation Per TDS Per process sheetC1.5 Solution Level Automatic or Manual 1/ShiftC1.6 Rinse Process Sheet 1/Shift2.0 Etch
Type:Size,volume:Proprietary name:Chemical supplier:
C2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC2.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC2.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC2.4 Agitation Per TDS Per process sheetC2.5 Solution Level Automatic or Manual 1/ShiftC2.6 Rinse Process Sheet 1/Shift3.0 Neutralizer
Type:Size,volume:Proprietary name:Chemical supplier:
C3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC3.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC3.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC3.4 Agitation Per TDS Per process sheetC3.5 Solution Level Automatic or Manual 1/ShiftC3.6 Rinse Process Sheet 1/Shift4.0 Activator
Type:Size,volume:Proprietary name:Chemical supplier:
C4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC4.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC4.3 1.4; 2.11; 2.13 Time Automatic Per process sheet
PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic for Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Cover PageCover Page Index PageIndex Page
ITEM # Category/Process Steps Control Monitoring
PROCESS TABLE C - Surface Conditioning of ABS & PCABS Plastic for Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Cover PageCover Page Index PageIndex Page
C4.4 Agitation Per TDS Per process sheetC4.5 Solution Level Automatic or Manual 1/ShiftC4.6 Rinse Process Sheet 1/Shift5.0 Accelerator
Type:Size,volume:Proprietary name:Chemical supplier:
C5.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftC5.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/ShiftC5.3 1.4; 2.11; 2.13 Time Automatic Per process sheetC5.4 Agitation Per TDS Per process sheetC5.5 Solution Level Automatic or Manual 1/ShiftC5.6 Rinse Process Sheet 1/Shift6.0 Electroless Plating
Type:Size,volume:Proprietary name:Chemical supplier:
C6.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftC6.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/ShiftC6.3 1.4; 2.11; 2.13 - Time Automatic Per process sheetC6.4 - Agitation Per TDS Per process sheetC6.5 - Solution Level Automatic or Manual 1/ShiftC6.6 - Rinse Process Sheet 1/Shift7.0 Electrolytic Plating - Strike
Type:Size,volume:Proprietary name:Chemical supplier:
C7.1 1.4; 2.11; 2.13 - Temperature Automatic 1/ShiftC7.2 1.4; 2.11; 2.13 - Concentration Automatic or Manual 1/DayC7.3 4.1, 4.4 - Current Automatic 1/ShiftC7.4 1.4; 2.11; 2.13 - Time Automatic 1/ShiftC7.5 - Agitation Per TDS 1/ShiftC7.6 - Solution Level Automatic or Manual 1/ShiftC7.7 - Rinse Process Sheet 1/Shift
Index PageIndex Page
ITEM # Category/Process Steps Control Monitoring
1.0 Acid Copper (as applicable)Type:Size,volume:Proprietary name:Chemical supplier:
D1.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD1.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD1.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD1.4 Agitation Per TDS Per process sheetD1.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD1.6 Solution Level Automatic or Manual 1/ShiftD1.7 Rinse Per Process Sheet 1/ShiftD1.8 Filtration Continuous 1/ShiftD1.9 Post Clean Per Process Sheet 1/Day2.0 Semi-Bright Nickel
Type:Size,volume:Proprietary name:Chemical supplier:
D2.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD2.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD2.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD2.4 Agitation Per TDS Per process sheetD2.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD2.6 Solution Level Automatic or Manual 1/ShiftD2.7 4.2 pH Automatic 1/ShiftD2.8 4.2 Internal stress test Manual 1/MonthD2.9 4.2 Ductility test Manual 1/Month
D2.10 4.2 Sulfur Concentration (as deposited) Manual 1/MonthD2.11 Filtration Continuous 1/Shift
3.0 High Activity Nickel (as applicable)Type:Size,volume:Proprietary name:Chemical supplier:
D3.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD3.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD3.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD3.4 Agitation Per TDS Per process sheetD3.5 4.1, 4.4 Current/Voltage Per Process Sheet Per JobD3.6 Solution Level Automatic or Manual 1/ShiftD3.7 pH Automatic 1/ShiftD3.8 Filtration Continuous Per process sheet4.0 Bright Nickel
Type:
PROCESS TABLE D - Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Index PageIndex PageCover PageCover Page
ITEM # Category/Process Steps Control Monitoring
PROCESS TABLE D - Decorative Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Index PageIndex PageCover PageCover Page
Size,volume:Proprietary name:Chemical supplier:
D4.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD4.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD4.3 1.4; 2.11; 2.13 Time Automatic Per process sheetD4.4 Agitation Per TDS Per process sheetD4.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD4.6 Solution Level Automatic or Manual 1/ShiftD4.7 pH Automatic 1/ShiftD4.8 Internal stress test Manual 1/MonthD4.9 Ductility test Manual 1/Month
D4.10 Filtration Continuous 1/Shift5.0 Microporous Nickel
Type:Size,volume:Proprietary name:Chemical supplier:
D5.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD5.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 1/ShiftD5.3 1.4; 2.11; 2.13 Time Automatic Per Process SheetD5.4 Agitation Per TDS Per Process SheetD5.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD5.6 Solution Level Automatic or Manual 1/ShiftD5.7 4.2 pH Automatic 1/ShiftD5.8 Rinse Per Process Sheet 1/ShiftD5.9 4.2 STEP Test (of final product) Manual 1/Day6.0 Chromium
Type:Size,volume:Proprietary name:Chemical supplier:
D6.1 1.4; 2.11; 2.13 Temperature Automatic 1/ShiftD6.2 1.4; 2.11; 2.13 Concentration(s) Automatic or Manual 2/ShiftD6.3 1.4; 2.11; 2.13 Time Automatic Per Process SheetD6.4 Agitation (if applicable) Per TDS Per Process SheetD6.5 4.1,4.4 Current/Voltage Per Process Sheet Per JobD6.6 Solution Level Automatic or Manual 1/ShiftD6.7 Rinse Per Process Sheet 1/ShiftD6.8 4.2 Pore Count and Pore Size Manual 1/Day
ITEM #Category/Process Steps Control Monitoring
1.0 Metal Cleaning (Off Line)
E1.1 1.4; 2.11; 2.13 Temperature Automatic 1/Shift
E1.2 1.4; 2.11; 2.13 Concentration Automatic or Manual 1/Shift
E1.3 1.4; 2.11; 2.13 Time Automatic or Manual Per Process Sheet
E1.4 Agitation Per TDS Per Process Sheet
E1.5 Solution Level Automatic or Manual 1/Shift
E1.6 Rinse Per Process Sheet 1/Shift
2.0 Mechanical Plating
E2.1 Load Size (e.g. weight, area, volume) Per Process Sheet per load
E2.2 Water Volume Per Process Sheet per load
E2.3 1.4; 2.11; 2.13 Temperature Per Process Sheet per load
E2.4.1 Media Mix (Ratio) - Sieve Testing Per Process Sheet 1 x per week
E2.4.2 Media (Load Volume) Per Process Sheet per load
E2.4.3 Per Process Sheet 1 x per week
E2.5.1 Surface Conditioner (Volume or weight) Per Process Sheet per load
E2.5.2 Surface Conditioner (Time) Per Process Sheet per load
E2.6.1 Per Process Sheet per load
E2.6.2 Surface preparation (Time) Per Process Sheet per load
E2.7.1 Promoter(s) (Volume) Per Process Sheet per load
E2.7.2 Promoter (Time) Per Process Sheet per load
E2.8.1 Zinc Flash (Weight or volume) Per Process Sheet per load
E2.8.2 Zinc Flash (Time) Per Process Sheet per load
E2.9.1 Metal Addition (Weight or volume) Per Process Sheet per load
E2.9.2 Metal Addition (Number of Adds) Per Process Sheet per load
E2.10 3.2 pH adjustments (Dependent on Adds) Per Process Sheet as needed
E2.11 Metal (Thickness) Per Process Sheet per load
E2.12 Water Polish (time) Per Process Sheet per load
PROCESS TABLE E - Mechanical Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Media (Cleanliness - To Avoid Contamination)
Surface preparation (Volume or weight) - Cu Flash
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ITEM #Category/Process Steps Control Monitoring
PROCESS TABLE E - Mechanical Plating
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Cover PageCover Page Index PageIndex Page
E2.13 Part/Media Separation Per Process Sheet per load
3.0 Passivates
E3.1 Acid Activation per Control Plan
E3.1.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift
E3.1.2 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift
E3.2 Passivate
E3.2.1 1.4; 2.11; 2.13 - Concentration Per Process Sheet 1/Shift
E3.2.2 1.4; 2.11; 2.13 - Temperature Per Process Sheet 1/Shift
E3.2.3 1.4; 2.11; 2.13 - Time Per Process Sheet 1/Shift
E3.2.4 3.2 - pH Per Process Sheet 1/Shift
E3.2.5 - Agitation Per Process Sheet 1/Shift
E3.2.6 - Contamination (e.g. Fe, Zn) Per Process Sheet 1/week
E3.3 Rinse Per Process Sheet 1/Shift
E3.4 Dry Per Process Sheet Per Process Sheet
4.0
E4.1.1 1.4; 2.11; 2.13 - Concentration Automatic or Manual
E4.1.2 1.4; 2.11; 2.13 - Solution Temperature Automatic or Manual
E4.1.3 1.4; 2.11; 2.13 - Time Automatic or Manual
E4.1.4 3.2 - pH Automatic or Manual
E4.1.5 - Drying Temperature Automatic
E4.1.6 - Spin Speed Automatic
E4.1.7
- Agitation Automatic or Manual
Supplemental Treatments - Sealers and Torque Tension Modifiers
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
Per Control Plan and TDS
LABORATORY EQUIPMENTITEM # EQUIPMENT TYPE
F1 2.14; 3.1; 4.1; 4.2 X X pH Meter/Probe Daily YearlyF1.2 2.14; 3.1; 4.1; 4.2 X X Wet Analysis N/A N/AF1.3 2.14; 3.1; 4.1; 4.2 X X Atomic Absorption (Optional)
MINIMUM REQUIRED TESTING CAPABILITYF1.4 3 X Salt Spray Cabinet N/A YearlyF1.5 3.2 & 4.2 X X Thickness Tester Daily YearlyF1.6 2.14; 3.1; 4.1; 4.2 X STEP N/A YearlyF1.7 2.14; 3.1; 4.1; 4.2 X CASS N/A YearlyF1.8 2.14; 3.1; 4.1; 4.2 X Microscope N/A YearlyF1.9 2.14; 3.1; 4.1; 4.2 X Freezer (POP only) N/A YearlyF1.10 2.14; 3.1; 4.1; 4.2 X Lab Oven (POP only) N/A YearlyF1.11 2.14; 3.1; 4.1; 4.2 X Stress (External Testing Acc.) N/A Yearly
F1.12 2.14; 3.1; 4.1; 4.2 X Daily Yearly
F2 2.14; 3.1; 4.1; 4.2 X N/A Yearly
F2.1 2.14; 3.1; 4.1; 4.2 X Pore Count/Active Sites N/A N/AF2.2 2.14; 3.1; 4.1; 4.2 X Pull Tester N/A YearlyF2.3 3.2 & 4.2 X X Lab Rectifier N/A Yearly
PROCESS EQUIPMENTITEM EQUIPMENT TYPE
F3 X X
3.3 & 4.3 X X Rack Rack Size
3.3 X BarrelHorizontalOblique
Barrel Size -volume
-dimensionsF3.1 X X Hoist
Manual Automatic Rack SizeBarrel Size
F3.2 3.4 & 4.4 X X Rectifier TypeWater cooled
Air cooled
PROCESS TABLE F - EQUIPMENT
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The auditor shall verify plater is conforming to customer requirements.
Related PSA Question #
Zinc/Zinc Alloy
Decorative Plating
Verification Frequency
Calibration Frequency
Sulfur by Foil (External Testing Acc.)
Ductility (External Testing Acc.)
PSA Clause Number
Zinc & Zinc Alloy
Plating
Decorative Plating
Verification Frequency
Calibration Frequency
Machine - Return type automatic
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PROCESS TABLE F - EQUIPMENT
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. The auditor shall verify plater is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Amperage controlled ITEM
EQUIPMENT TYPE
Voltage controlledF3.3 X X Filters
Pre-packCartridge
OtherF3.4 3.5 X Oven type
ContiniousBatch
3.5 X Chart recorder3.6 X Themocouples
number3.3 X Basket type
Expanded metalPerforated
SolidSize
F3.5 X X ControllersAutomatic feeders
TimersTemperature
VolumeF3.6 X X Agitation type
Air Cathode rod
F3.7 X X Water sourceTapRO
Deionized
PSA Clause Number
Zinc & Zinc Alloy
Plating
Decorative Plating
Verification Frequency
Calibration Frequency
CQI-12 COATING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet
1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and CoatingSpecialist) or different management system, then these locations shall be considered as separate facilities.
2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
4 Fax number: The fax number of the facility.
5 Number of Coating Employees at this Facility: The number of employees, salaried and hourly, associated with the coating operation at this facility.
6 Captive Coater (Y/N): Enter "Y" if this facility coats components for their own company. Enter"N" if the company does not coat any components for their own company.
7 Commercial Coater (Y/N): Enter "Y" if this facility coats components for companies other thantheir own company. Enter "N" if this facility does not coat any components for other companies.
8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.
9 Date of Previous Assessment: List the date of the previous CQI-12 Special Process: CoatingSystem Assessment of this facility.
10 Type(s) of Coating at this Facility: Place a checkmark to designate the coating process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the CoatingSystem Assessment.
11 Current Quality Certification(s): the coater shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the coater shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the coater's organization.
14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
Cover PageCover Page Index PageIndex Page
Special Process: Coating System Assessment
Facility Name:Address:
Phone Number: Type(s) of Coating Processes at this Facility:Fax Number: Process Table A
Aqueous CleaningNumber of Coating Employees at this Facility: Process Table B
Mechanical CleaningCaptive Coater (Y/N): Process Table CCommercial Coater (Y/N): Phosphating
Process Table DDate of Assessment: Powder Coating
Process Table E Date of Previous Assessment: Electrocoat
Process Table FSprayProcess Table GDip/SpinProcess Table HAutophoreticProcess Table IConvective CureProcess Table JEquipment
Current Quality Certification(s):
Date of Re-assessment (if necessary):
Personnel Contacted:Name: Title: Phone: Email:
0 00 00 00 0
Auditors/Assesors:Name: Company: Phone: Email:
0000
Number of "Not Satisfactory" Findings:
Number of "Needs Immediate Action" Findings:
Number of "Fail" Findings in the Job Audit(s):
Index PageIndex PageCover PageCover Page
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.1
1.2
1.3
1.4
Question Number
Not Satisfactory
Needs Immediate
Action
Is there a dedicated and qualified coating person on-site?
To ensure readily available expertise, there shall be a dedicated and qualified coating person on the site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including chemical and coating knowledge. The qualifications shall include a minimum of 5 years experience in coating operation or a combination of a minimum of 5 years of formal chemical education and coating experience.
Does the coater perform advanced quality planning?
The organization shall incorporate a documented advanced quality planning procedure. A feasibility study shall be performed and internally approved for each new part or process. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The coater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Are the coater's FMEA's up to date and reflecting current processing?
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEAs are updated to reflect current part quality status. The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key coating process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
Are finish process control plans up to date and reflecting current processing?
The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key coating process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEAs. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.
Index PageIndex PageCover PageCover Page
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate
Action
Index PageIndex PageCover PageCover Page
1.5
1.6
1.7
1.8
1.9
Are all coating related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.
To ensure all customer requirements are both understood and satisfied, the organization shall have all related coating and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards and specifications and changes based on customer-required schedule. This process shall be executed as soon as possible and shall not exceed two weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.
Is there a written process specification for all active processes?
The coater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, rectifier settings, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.
Has a valid product capability study been performed initially and after process change?
To demonstrate each process is capable of yielding acceptable product, the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all coating processes per line as defined in scope of work and in accordance with customer requirements. Capability study techniques shall be appropriate for the coating product characteristics, e.g., coating thickness, corrosion resistance, etc.. Any specific customer requirements shall be met. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.
Does the coater collect and analyze data over time, and react to this data?
The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time. Methods of analysis shall include ongoing trend or historical data analysis of special product or process parameters. The organization shall determine which parameters to include in such analysis.
Are internal assessments being completed on an annual basis, at a minimum, incorporating AIAG CSA?
The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG CSA. Concerns shall be addressed in a timely manner.
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate
Action
Index PageIndex PageCover PageCover Page
1.10
1.11
1.12
1.13
1.14
1.15
1.16
Is there a system in place toauthorize reprocessing and is it documented?
The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual. The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. All reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary coating modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.
Does the Quality Department review, address, and document customer and internal concerns?
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.
Is there a continual improvement plan applicable to each process defined in the scope of the assessment?
The coater shall define a process for continual improvement for each coating process identified in the scope of the CSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.
Does the Quality Manager or designee authorize the disposition of material from quarantine status?
The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.
Are there procedures or work instructions available to coating personnel that define the coating process?
There shall be procedures or work instructions available to coating personnel covering the coating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.
Is management providing employee training for coating?
The organization shall provide employee training for all coating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.
Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?
The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate
Action
Index PageIndex PageCover PageCover Page
1.17
1.18
Section 2 - Floor and Material Handling Responsibility
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program?
The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner. Company data, e.g., downtime, quality rejects, first time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.
Has the coater developed a critical spare part list, and are the parts available to minimize production disruptions?
The coater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.
Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?
Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.
Is product clearly identified and staged throughout the coating process?
Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the coating process. Non-coated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.
Is lot traceability and integrity maintained throughout all processes?
Out-going lot(s) shall be traceable to the incoming lot(s).The descipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.
Are procedures adequate to prevent movement of non-conforming product into the production system?
The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material.
Is there a system to identify trap points in the entire process to reduce risk of mixed parts (inappropriate, unfinished or improperly coated parts)?
The coater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.
Are containers free of inappropriate material?
Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming coated parts or inappropriate material contaminate the finished lot.
Is part loading specified, documented and controlled?
Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.
Refer to Process Tables for frequency of checks.
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number
Not Satisfactory
Needs Immediate
Action
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2.8
2.9
2.10
2.11
2.12
2.13
2.14
Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?
Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.
Is the handling, storage and packaging adequate to preserve product quality?
The coater's loading/unloading systems, in-process handling and shipping process shall be assessed for risk of part damage or other quailty concerns.
Are plant cleanliness, housekeeping, environmental and working conditions conducive to control and improved quality?
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The coater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes etc.
Are process control parameters monitored per frequencies specified in Process Tables?
Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.
Are out of control/specification parameters reviewed and reacted to?
There are documented reaction plans to both out of control and out of tolerance process parameters. There is documented evidence that reaction plans are followed.
Are In-Process / Final Test Frequencies performed as specified in Process Tables?
In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables
Is product test equipment verified?
Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.
Refer to Process Tables for frequency of checks.
Section 3 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Coating Requirements:
Question # Job Audit Question
3.1 N/A
3.2 1.5
N/A
3.3
3.4
3.5 2.1
3.6
3.7
3.8
3.8.1 Requirement: Coating ThicknessTest Method:Test frequency or quantity:Selection of samples:Specification:
3.8.2
Test Method(s):Test frequency or quantity:Selection of samples:Specification:
3.8.3
Test Method:Test frequency or quantity:Selection of samples:Specification:
3.8.4 Requirement: AdhesionTest Method(s):Test frequency or quantity:Selection of samples:Specification:
3.8.5 Requirement: CureTest Method:
RelatedCSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Is contract review and advanced quality planning, FMEA, control plans, etc., performed by qualified individuals?
1.11.21.31.41.6
Does the Coater have the proper customer specifications for the part?
Is a shop traveler created to meet customer requirements?
1.62.1
Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the coating process?
2.22.32.4
Is there documented evidence of Receiving Inspection?
Are the Loading / Racking requirements identified?
1.62.72.9
Is the proper procedure or process specification used? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.
1.51.62.1
2.112.13
What are the product inspection requirements?
1.5 2.13
2.14
Each part may have one or more requirements determined by the coating specification. Parts must meet each requirement. List each requirement below and validate.
(Listed below are some examples)
Requirement: Corrosion Resistance (if applicable).
Requirement: Hydrogen Embrittlement Relief (if applicable)
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Section 3 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Coating Requirements:
Question # Job Audit QuestionRelated
CSA Question #Customer or Internal
Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Index PageIndex PageCover PageCover Page
Test frequency or quantity:Selection of samples:Specification
3.8.6
Test Method:Test frequency or quantity:Selection of samples:Specification:
3.8.7
Test Method:Test frequency or quantity:Selection of samples:Specification
3.8.8
Test Method:Test frequency or quantity:Selection of samples:Specification:
3.8.9
Test Method:Test frequency or quantity:Selection of samples:Specification:
3.8.10 Requirement: Customer SpecificTest Method(s):Test frequency or quantity:Selection of samples:Specification:
Operator or Inspector Responsibilities
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16 2.6
Packaging Requirements
Requirement: Torque Tension (if applicable)
Requirement: Appearance (Decorative)
Requirement: Dimensional (if applicable)
Requirement: Color and Gloss (Decorative)
Were appropriate process steps signed off?
1.41.62.22.3
2.11
Were all inspection steps, as documented in the control plan performed?
1.21.4
Were steps/operations performed that were not documented in the control plan?
1.21.41.6
If additional steps were performed, were they authorized?
1.21.41.6
1.101.16
Does the governing specification allow reprocessing or rework?
1.51.10
If the order was certified, did the certification accurately reflect the process performed?
2.112.13
Was the certification signed by an authorized individual?
1.16
Are the parts and containers free of inappropriate objects or contamination?
Section 3 - Job Audit - Finished Product Review
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Coating Requirements:
Question # Job Audit QuestionRelated
CSA Question #Customer or Internal
Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
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3.17
3.18
Shipping Requirements
3.19
3.20
Are packaging requirements identified?
2.6 2.7
2.9
Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?
2.6 2.7
2.9
Were the parts properly identified? 2.32.9
Were the containers properly labeled?
2.32.9
Assessor(s) shall have the following specific experience to conduct the COATING SYSTEM ASSESSMENT:
1 Be an experienced quality management system (QMS) internal auditor (for example,ISO/TS 16949-2002, ISO 9001:2000).
2 Assessor shall possess coating knowledge. Evidence shall include a minimum of 5years experience in coating or a combination of formal chemical education and coating experience totaling a minimum of 5 years.
3 Assessor shall possess knowledge of and be familiar with the application of automotivequality core tools including statistical process control, measurement systems analysis,part approval, failure mode and effects analysis, and advanced quality planning.
Note: If more than one assessor is required to meet the above qualifications, the lead assessor shall be the person meeting the requirements in item # 1 above.
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Item # Category/Process Steps Control Monitoring
1.0
A1.1 1.4 Per Control Plan Per lot
2.0 Cleaning Bath(s)
A2.1 2.11
A2.2 Pressure/Agitation Automatic/Manual
A2.3 Temperature Automatic/Manual
A2.4 Time Automatic/Manual
A2.5 Chemical Concentration Automatic/Manual
A2.6 Impurity Content (e.g. acid split) Manual
A2.7 2.11 There is a dump schedule for cleaning baths. Manual Per Control Plan/Log Sheet
3.0 Rinse Bath(s)
A3.1 2.11
A3.2 Pressure/Agitation Automatic/Manual
A3.3 Temperature Automatic/Manual
PROCESS TABLE A - Pretreatment (Aqueous)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
AQUEOUS CLEANING PROCESS (Alkaline or Acid)
There shall be an incoming part assessment procedure with criteria.
The following checks shall be performed during production:
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 1.6 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 1.6 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
The following checks shall be performed during production:
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
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Item # Category/Process Steps Control Monitoring
PROCESS TABLE A - Pretreatment (Aqueous)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Cover PageCover Page Index PageIndex Page
A3.4 Time Automatic/Manual
A3.5 Impurity Concentration Manual
A3.6 Overflow Rate Automatic/Manual
A3.7 2.11 There is a dump schedule for rinses. Manual Per Control Plan/Log Sheet
A3.8 Manual
A3.9 Manual
A3.10 Automatic/Manual
1.4 1.6 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
There is a visual inspection (e.g. water break) after each post cleaning rinse bath where possible. (not applicable for bulk)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
There is a final rinse. It shall be monitored for presence of bacteria. (for plastic substrate)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
For Metals -- Corrosion inhibitor concentration is checked. (If applicable)
Per Control Plan/Log Sheet (1/shift minimum)
Item # Category/Process Steps Control Monitoring
1.0 ABRASIVE BLAST PROCESS
B1.1 1.4 Per Control Plan Per lot
B1.2 2.11
B1.3 Abrasive media flow Automatic/Manual
B1.4 Nozzle air pressure Automatic/Manual
B1.5 Dwell time Automatic/Manual
B1.6 Dust collector efficiency/air flow Automatic
B1.7 Working mix Automatic/Manual
PROCESS TABLE B - Pretreatment (Mechanical)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA
Question #
There shall be an incoming part assessment procedure with criteria.
The following checks shall be performed during production:
1.4 1.6 2.11
2.12
Per Control Plan/Log Sheet (1/shift
minimum)
1.4 1.6 2.11
2.12
Per Control Plan/Log Sheet (1/shift
minimum)
1.4 1.6 2.11
2.12
Per Control Plan/Log Sheet (1/shift
minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (2/shift
minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift
minimum)
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Item # Category/Process Steps Control Monitoring
PROCESS TABLE B - Pretreatment (Mechanical)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA
Question #
Index PageIndex PageCover PageCover Page
B1.8 Surface cleanliness is checked after process. Manual
B1.9 Manual Per lot
1.4 2.11
Per Control Plan/Log Sheet (1/shift
minimum)
1.4 2.11
2.13
Surface profile is checked after process (if applicable).
Item # Category/Process Steps Control Monitoring
1.0 Conversion Coating
C1.1 1.4 Per Control Plan Per lot
2.0 Rinse Conditioner (If Applicable)
C2.1 2.11
C2.2 Pressure/Agitation Automatic/Manual
C2.3 Time Automatic/Manual
C2.4 Chemical Concentration Automatic/Manual
C2.5 2.11 Manual
PROCESS TABLE C - Pretreatment (Phosphating)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
There shall be an incoming part assessment procedure with criteria.
The following checks shall be performed during production:
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
There is a dump schedule for rinse conditioner.
Per Chemical Manufacturer's Guideline
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Item # Category/Process Steps Control Monitoring
PROCESS TABLE C - Pretreatment (Phosphating)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
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3.0 Conversion Coating Bath
C3.1 2.11
C3.2 Pressure/Agitation Automatic/Manual
C3.3 Temperature Automatic/Manual
C3.4 Time Automatic/Manual
C3.5 Automatic/Manual
C3.6 Automatic/Manual
C3.7 Coating Weight Manual
The following checks shall be performed during production:
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Chemical Concentration (Free Acid, Total Acid, Iron Content, pH, Accelerator Amount as Applicable)
Per Control Plan/Log Sheet (2/shift minimum)
1.4 2.11
2.12
Fluoride Ion Concentration (if aluminum is being coated)
Per Control Plan/Log Sheet (2/shift minimum)
1.41.6
2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
Item # Category/Process Steps Control Monitoring
PROCESS TABLE C - Pretreatment (Phosphating)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
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C3.8 Crystal Size (If applicable) Manual
4.0 Rinse After Phosphate
C4.1 2.11
C4.2 Manual
C4.3 Pressure/Agitation Automatic/Manual
C4.4 Time Automatic/Manual
C4.5 2.11 There is a dump schedule for rinses Manual
5.0 Seal Rinse
1.4 2.11
2.12
Per customer requirement
The following checks shall be performed during production:
1.4 2.11
2.12
Impurity Concentration (e.g. Titration, Conductivity)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
Per Chemical Manufacturer's Guideline
Item # Category/Process Steps Control Monitoring
PROCESS TABLE C - Pretreatment (Phosphating)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
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C5.1 2.11
C5.2 Pressure/Agitation Automatic/Manual
C5.3 Time Automatic/Manual
C5.4 Chemical Concentration Automatic/Manual
C5.5 Temperature (If applicable) Automatic/Manual
C5.6 2.11 There is a dump schedule for seal rinse. Manual
6.0 Dry-Off (If Applicable)
C6.1 Automatic
The following checks shall be performed during production:
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
Per Chemical Manufacturer's Guideline
1.4 2.11
2.12
Air temperature is monitored and controlled.
Per Control Plan/Log Sheet (1/shift minimum)
Item # Category/Process Steps Control Monitoring
PROCESS TABLE C - Pretreatment (Phosphating)
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
C6.2 Visual Each Lot1.4 2.11
There is a procedure to ensure dryness of parts prior to susequent coating.
Item # Category/Process Steps Control Monitoring
1.0 Powder Paint Application
D1.1 Manual
2.0 Powder Booth and Equipment
D2.1 The temperature of parts entering the coating booth is monitored. Automatic/Manual
D2.2 Automatic
D2.3 Automatic/Manual
D2.4 The air dryer and filter are on main compressed air line. Automatic/Manual
D2.5 The booth temperature and humidity are checked. Manual
D2.6 The air balance in the powder booth is checked. Manual
D2.7 The rotary seive is clean and operational. Automatic/Manual
D2.8 The powder flow on seive is monitored. Automatic/Manual
D2.9 The vent assist air pressure is checked. Manual
D2.10 The vent on feed hopper is checked. Manual
D2.11 The reclaim seive is operating properly. Manual
D2.12 All guns are operational and in good repair. Manual
D2.13 Manual Per PM schedule
D2.14 Manual
PROCESS TABLE D - Powder
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.4 2.11
Parts are checked exiting dry-off oven for cleanliness and trapped water, prior to entering powder booth.
Per Control Plan/Log Sheet (1 per hour)
1.4 2.11
2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
1.172.112.12
The conveyor is operating at the proper line speed (no abrupt movement or contact between parts).
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11
2.12
The ground is checked using a 500 volt megohm meter (less than 1megohm resistance).
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/day minimum)
1.41.172.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
The venturis in the feed pumps and the pick up tubes in the hopper are checked.
1.4 2.11 2.12
The feed hoses are checked to ensure that they have no excessive bends and kinks.
Per Control Plan/Log Sheet (1/day minimum)
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Item # Category/Process Steps Control Monitoring
PROCESS TABLE D - Powder
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
D2.15 The virgin/reclaim ratio is checked. (feed pressure) Manual
D2.16 Manual
D2.17 Appearance of parts exiting booth is checked. Manual
D2.18 The powder supply and atomizing air pressure are checked. Manual
3.0 Cure (See Convective Cure Process Table I)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
The static pressure gauges on primary and final filters are checked.
Per Control Plan/Log Sheet (1/shift minimum)
1.41.112.122.13
Per Control Plan/Log Sheet (1 per hour)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
Item # Category/Process Steps Control Monitoring
1.0 Pre-Electrocoat Paint Application Part Appearance
E1.1 Manual
2.0 Electrocoat Laboratory
E2.1 2.14 N/A
E2.2 2.14 N/A
E2.3 2.14 N/A
3.0 Electrocoat Tank
E3.1 Automatic/Manual
E3.2 Line speed setup is checked. Automatic/Manual
E3.3 Line speed is verified. Manual Once/week minimum
E3.4 Automatic/Manual
E3.5 Automatic/Manual
E3.6 Flow direction is checked (for monorail system). Manual
E3.7 Flow over the weir is checked. Manual
E3.8 Bath is checked for microbial contamination. Manual
E3.9 Incoming DI / RO water is checked for cleanliness. (conductivity) Automatic/Manual
E3.10 Paint racks are being maintained. Automatic/Manual As needed
E3.11 There is a paint rack maintenance schedule. Manual Required
E3.12 There is a tank clean up schedule. Manual
4.0 Anolyte System
PROCESS TABLE E - Electrocoat
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.4 2.11
Incoming parts are inspected for cleanliness and/or uniform phosphate coating (when phosphate is used).
Per Control Plan/Log Sheet (1 per hour)
Laboratory equipment is calibrated and in good working order.
Laboratory standards and reagents are properly stored, labeled, and not expired.
Laboratory records, internal and external, are filed and accessible for review.
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Bath parameters (pH, conductivity, solid content, temperature, voltage) are checked and adjusted.
Per Control Plan/Log Sheet
1.41.6
2.112.12
Per Control Plan/Log Sheet
1.4 2.11 2.12
1.4 2.11 2.12
There is circulation and it is monitored. (flow meter, pressure gage)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Bag filter pressures are monitored. Bags changed when psi differential. >5-10 PSI.
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/ per week
minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
1.41.172.112.12
1.41.172.112.12
Required (1/year minimum)
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Item # Category/Process Steps Control Monitoring
PROCESS TABLE E - Electrocoat
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
E4.1 Automatic/Manual
E4.2 Automatic/Manual
E4.3 The pH of the anolyte solution has been checked. Automatic/Manual
E4.4 Anodes have been inspected. Manual
E4.5 The anolyte solution is being circulated to each cell. Automatic/Manual
E4.6 Dump and clean schedule for anolyte being maintained. Manual
E4.7 Amperage draw has been checked on each anode. Automatic/Manual
5.0 Rectifier
E5.1 The proper voltage is being used for the load size. Manual per Equip. Mfg.
E5.2 The ramp up time to full voltage has been verified. Automatic/Manual
E5.3 2.10
E5.4 Automatic/Manual
6.0 Rinse System
E6.1 Automatic/Manual
E6.2 There is sufficient permeate supplied to the rinse. Automatic/Manual
E6.3 The pH and conductivity of the rinse have been recorded. Manual
E6.4 There is microbial testing of rinses. Manual
E6.5 Automatic/Manual
E6.6 Rinses have been cleaned per maintenance schedule. Manual
7.0 Cure (See Convective Cure Process Table I)
1.4 2.11 2.12
The anolyte solution is being controlled within the required conductivity limits.
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
The conductivity reading on the anolyte tank has been confirmed in the laboratory.
Per Control Plan/Log Sheet 1 / week
1.4 2.11 2.12
Per Control Plan/Log Sheet (1 per shift)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1 per six months)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet
1.4 2.11 2.12
Per Control Plan/Log Sheet
1.41.6
2.112.12
1.4 2.11 2.12
Per Control Plan/Log Sheet (1 per shift)
There is a safety beacon to alert personnel when system is energized.
1.41.172.112.12
The ripple of the rectifier has been checked by an approved electrician.
Per Control Plan / material supplier
1.4 2.11 2.12
Immersion rinse tanks are operating at the proper levels and tanks are being agitated correctly.
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan / material supplier
1.4 2.11 2.12
The ultrafilters are operating at proper pressures and bag filters are being used. What size bags?
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan / material supplier
Item # Category/Process Steps Control Monitoring
1.0 Part Appearance
F1.1 Manual
F1.2 1.14 Inspection criteria are posted.
F1.3 2.10 Adequate lighting is in place.
F1.4
F1.5 Paint racks are maintained. Manual
2.0 Paint Mixing
F2.1 Automatic/Manual
F2.2 Manual
F2.3 Manual
F2.4 Manual
F2.5 Manual
F2.6 Manual
F2.7 Automatic/Manual Per Control Plan/Log Sheet
F2.8 Automatic/Manual Per Control Plan/Log Sheet
3.0
F3.1 Manual
F3.2 Automatic
PROCESS TABLE F - Spray
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.4 2.11
Incoming parts are inspected for cleanliness, trapped water or water spots as well as uniform phosphate coating (when phosphate is used).
Per Control Plan/Log Sheet (1 per hour)
1.4 2.9
Mutilation prevention items (i.e. gloves, belt buckle covers, watch covers, etc.) are in place.
1.41.172.112.12
1.4 2.11 2.12
Paint mixing rooms are controlled (mixing tank grounding, closed container, properly enclosed space, temperature, clean environment).
Per Paint Manufacturer Recommendation
1.4 2.11 2.12
FIFO system is being utilized.Per Paint Manufacturer
Recommendation
1.4 1.6 1.17 2.11
2.12
Paint agitation/time and reduction (solvent package) are proper and documented.
Per Paint Manufacturer Recommendation
1.4 1.6 1.17 2.11
2.12
Viscosity and temperature are in operational limits and documented.
Per Control Plan/Log Sheet/Paint Manufacturer
Recommendation
1.4 1.6 1.17 2.11
2.12
The proper filter size and type are in place.Per Control Plan/Log
Sheet/Paint Manufacturer Recommendation
1.4 1.6 1.17 2.11
2.12
Pump pressures are set within operational limits.Per Control Plan/Log
Sheet/Paint Manufacturer Recommendation
1.4 2.11 2.12
Circulation (flow meter, pressure gage) is monitored.
1.4 2.11 2.12
Bag filter pressures are monitored (bags are changed when psi differential >5-10 PSI).
Substrate Conditioning (Flame, Plasma, etc) (If applicable)
1.4 2.11
Incoming parts are inspected to ensure that they are free of dirt and contamination.
1.4 1.17 2.11
2.12
Flame/Plasma is set at operational limits per equipment and material supplier recommendations.
Per control plan and equipment and substrate
suppliers recommendations
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Control Monitoring
PROCESS TABLE F - Spray
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
F3.3 Manual Per Control Plan
4.0 Primer/Promoter
F4.1 Manual
F4.2 Destaticizing air is operational. (Plastic parts only) Automatic
F4.3 Manual
F4.4 Automatic/Manual
F4.5 Manual
F4.6 Automatic/Manual
5.0 Basecoat (If applicable)
F5.1 Manual
F5.2 Automatic/Manual
F5.3 Automatic/Manual
F5.4 Automatic/Manual
F5.5 Manual
6.0 Basecoat Heated Flash (Waterborne Materials Only)
F6.1 Manual
F6.2 Manual
1.4 2.11 2.13
Final surface tension is within specifications.
1.4 2.11
Incoming parts are inspected to ensure that they are free of dirt and contamination.
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Control Plan/Log Sheet 1 / week
1.4 2.11 2.12
Booth balance is monitored. Per Control Plan/Log Sheet 1 / week
1.4 1.6 1.17 2.11
2.12
Booth temperature and humidity are monitored (or set within operational limits if controlled).
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Film thickness is per customer requirements.Per control plan and
customer requirements
1.4 1.6 1.17 2.11
2.12
Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.
Per Control Plan/Log Sheet (1 per month minimum)
1.4 2.11
Incoming parts are inspected to ensure that they are free of dirt and contamination.
Per Control Plan / material supplier (once per shift
minimum)
1.4 1.6
2.11 2.13
Flashtimes between coats are set at suppliers recommended times.
Per Control Plan/material supplier
1.4 1.6 1.17 2.11
2.12
Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 1.6 1.17 2.11
2.12
Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.
Per Control Plan/Log Sheet (1 per month minimum)
1.4 2.11 2.13
Film builds are per supplier recommendations.Per Control Plan and
suppliers recommendations
1.4 1.6
2.11 2.13
Set point is at suppliers recommended time, temperature and energy type (convection/IR/UV/etc.).
Per Control Plan / material supplier
1.4 1.6
2.11 2.13
Percent solids after pre-dry is at the suppliers recommended percentage.
Per Control Plan/Log Sheet (1/shift minimum)
Item # Category/Process Steps Control Monitoring
PROCESS TABLE F - Spray
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
F6.3 Manual
7.0 Clearcoat
F7.1 Manual
F7.2 Automatic/Manual
F7.3 Automatic/Manual
F7.4 Automatic/Manual
8.0 Cure (See Convective Cure Process Table I)
9.0 Final Part Inspection
F9.1 1.14
F9.2 2.10
F9.3
F9.4 Manual Per Control Plan
F9.5 Manual Per Control Plan
F9.6 Manual Per Control Plan
1.41.172.112.12
The pre-dry oven is maintained. Per Control Plan / material
supplier
1.4 2.11
Incoming parts are inspected to ensure that they are free of dirt and contamination.
Per Control Plan / material supplier (once per shift
minimum)
1.4 1.6
2.11 2.13
Flashtimes between coats are set at suppliers recommended times.
Per Control Plan/material supplier
1.4 1.6 1.17 2.11
2.12
Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)
Per Control Plan/Log Sheet (1/shift minimum)
1.4 1.6 1.17 2.11
2.12
Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.
Per Control Plan/Log Sheet (1 per month minimum)
Inspection criteria are posted.
There is adequate lighting in inspection area.
1.4 2.9
Mutilation prevention items are in place.
1.4 1.8 1.12
2.13
Defects are being tracked.
1.4 2.13
FTT is being monitored.
1.10 1.11
1.12Scrap and repaints are being tracked.
Item # Category/Process Steps Control Monitoring
1.0 Coating Material Application
G1.1 Manual
G1.2 Automatic/Manual
G1.3 Manual
2.0 Coating Bath
G2.1 Incoming paint viscosity is checked. Manual Each New Lot of Paint
G2.2 Incoming solids checks are performed. Manual Each New Lot of Paint
G2.3 Manual Ongoing
G2.4 Manual Ongoing
G2.5 Paint is kept covered and/or sealed when not in use. Manual Ongoing
G2.6 Manual Ongoing
G2.7 Paint storage room is kept clean. Manual Ongoing
G2.8
G2.9 Paint Temperature. Manual
G2.10 Viscosity. Manual
G2.11 % Solids (by weight). Manual
G2.12 Volume (paint depth in coating vat). Automatic/Manual
G2.13 Vibratory feed tables are cleaned (if used). Manual
PROCESS TABLE G - Dip/Spin
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.4 2.11
After pretreatment, parts are inspected for flash rust, wetness, oil or other defects.
Per Control Plan/Log Sheet (each lot)
1.4 2.11
If phosphated, parts are checked for uniformity of phosphate coating.
Per Control Plan/Log Sheet (1/shift minimum)
2.6 1.17
Skids/bins used to hold parts between coating operations are free of oil, grease or other contaminants.
Per Control Plan/Log Sheet (each lot)
1.4 2.11 2.12
1.4 2.11 2.12
1.41.172.112.12
Appropriate mixing equipment is used, capable of dispersing settled solids.
2.9 2.10
Paint is stored properly, away from high humidity and temperature extremes.
2.9 2.10
2.9 2.10
Paint storage room is organized so each paint is easily found to prevent contamination.
2.9 2.10
The following checks shall be performed during production:
1.4 2.11 2.12
Per Control Plan/Log Sheet (3/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (3/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/Day minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (3/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (as needed)
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Control Monitoring
PROCESS TABLE G - Dip/Spin
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
G2.14 Manual
G2.15 Paint and/or solvent additions are documented. Manual
G2.16 2.10 Viscosity cups are cleaned after each use. Manual
G2.17 Viscosity cups are verified. Manual 2/Month minimum
G2.18 Thermometers are calibrated/verified. Manual Once/Month minimum
3.0 Application Parameters
G3.1 Automatic/Manual
G3.2 Baskets are kept less than 2/3 full. Automatic/Manual
G3.3 Dip time is controlled. Automatic/Manual
G3.4 Spin speed (RPM) is controlled. Automatic/Manual
G3.5 The coating unit has an attached RPM indicator.
G3.6 RPM's can be adjusted easily.
G3.7 Spin time is controlled. Automatic/Manual
G3.8 Automatic/Manual
G3.9 Automatic/Manual
G3.10 Automatic/Manual
1.4 1.17
2.11 2.12
Basket condition (basket mesh clean and undamaged).
Per Control Plan/Log Sheet (as needed)
1.4 2.11 2.12
Per Control Plan/Log Sheet (each addition)
Per Control Plan/Log Sheet (each check)
2.14 1.17
2.14 1.17
1.4 1.6
A system is in place to ensure proper basket weights for specific parts, such as processing manual, traveller, or process recipe.
Per Control Plan/Log Sheet (each lot)
1.4 1.6
Per Control Plan/Log Sheet (each lot)
1.4 1.6
Per Control Plan/Log Sheet (each lot)
1.4 1.6
Per Control Plan/Log Sheet (each lot)
1.4 1.6 1.17
1.4 1.6 1.17
1.4 1.6
Per Control Plan/Log Sheet (each lot)
1.4 1.6
The number of spins is adjustable (single, double, triple).
1.4 1.6
Tumble time is in/out of coating controlled (if applicable).
Per Control Plan/Log Sheet (each lot)
1.4 1.6 1.17
There is an adequate system to keep parts level going into the oven (raking, vibe table, etc.).
Per Control Plan/Log Sheet (each lot)
Item # Category/Process Steps Control Monitoring
PROCESS TABLE G - Dip/Spin
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
G3.11 2.10 Vibratory feed tables are cleaned (if used). Manual
G3.12 2.9 Automatic/Manual
G3.13 Parts are cool to to touch before each coating step. Manual Per Control Plan (each lot)
4.0 Cure (See Convective Cure Process Table I)
Per Control Plan/Log Sheet (as needed)
There is evidence of steps taken to assist in soft handling of parts (shallow drops, lined chutes and hoppers, bumper boards, etc.).
Per Control Plan/Log Sheet (each lot)
1.4 2.9 2.11
Item # Category/Process Steps Control Monitoring
1.0 3.1 Coating Bath
H1.1 Automatic/Manual
H1.2 Time (hoist program) is verified. Automatic/Manual
H1.3 Conveyor speed is verified (if applicable). Manual
H1.4 Temperature is monitored and controlled. Automatic
H1.5 Humidity level is monitored. Automatic/Manual
H1.6 101 (fluoride) and ORP levels are checked. Automatic/Manual
H1.7 Automatic/Manual
H1.8 Bath transfer is maintained. Manual
2.0 1.18 Tap Rinse After Coating
H2.1 Pump pressure or agitator speed is monitored. Automatic/Manual
H2.2 Impurity concentration (conductivity) is checked. Automatic/Manual
3.0 3.2 Reaction Rinse
H3.1 Automatic/Manual
H3.2 Pump pressure or agitator speed is monitored. Automatic/Manual
H3.3 Automatic/Manual
H3.4 There is a dump schedule. Manual
PROCESS TABLE H - Autophoretic
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.4 2.11 2.12
Mixer speed and direction are monitored and adjusted.
Per Control Plan/Log Sheet (1/shift minimum)
1.41.6
2.112.12
Per Control Plan/Log Sheet (1/day minimum)
1.41.172.112.12
Annually or after repair
1.41.6
2.112.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (every 2 hours minimum)
1.4 2.11 2.12
Chemical concentration (% solids, starter/iron titration, conductivity) is checked and maintained.
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per PM schedule (1/year
minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Chemical concentration (titration, conductivity, pH, Hach Meter Test) is checked and maintained.
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Per Control Plan/Log Sheet (1/shift minimum)
1.4 2.11 2.12
Temperature is monitored and controlled (if applicable).
Per Control Plan/Log Sheet (1/shift minimum)
1.41.172.112.12
Per Chemical Manufacturer's Guideline (minimum 3 times per year)
Index PageIndex PageCover PageCover Page
Item # Category/Process Steps Control Monitoring
PROCESS TABLE H - Autophoretic
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Index PageIndex PageCover PageCover Page
4.0 Cure (See Convective Cure Process Table I)
PROCESS TABLE I - Convective Cure
Item #Category/Process Steps Control Monitoring
1.0
I1.1 Automatic
I1.2 1.17 Part temperature profile is monitored. Manual 1/month minimum
I1.3 Proper cure time is maintained (if applicable). Automatic/Manual Per coating supplier recommendation
I1.4 Conveyor speed is maintained (if applicable). Automatic 1/month minimum (after PM)
I1.5 Airflow is measured (if required by coating supplier). Automatic/Manual Per coating supplier recommendation
I1.6 1.17 Air filter change is scheduled. Manual
I1.7 1.17 Thermocouple for oven control is calibrated.
I1.8 2.13 Cure testing is conducted by laboratory. Manual Per coating supplier recommendation
I1.9 2.13 Final color is monitored. Manual
I1.10 2.13 Film thickness/coating weight is monitored. Manual
I1.11 2.13 Gaugeability is checked (if applicable). Manual Per customer requirements
I1.12 2.13 Paint adhesion is monitored. Manual
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
1.41.6
2.112.12
Oven temperature set point and limits are checked and documented.
1/shift minimum or at every material change. Per coating supplier
recommendation
1.41.6
2.112.12
1.41.6
1.172.112.12
1.4 2.11 2.12
Per oven manufacturer, filter supplier recommendation
Per Control Plan/Log Sheet (1/shift or color change minimum)
Per Control Plan/Log Sheet (1/shift or color change minimum)
Per Control Plan/Log Sheet (1/shift or color change minimum)
Index PageIndex PageCover PageCover Page
PROCESS EQUIPMENT
Item # Pretreatment E-Coat Spray Dip/Spin A-Coat Cure Verification Frequency Comment
1.1 2.14 X X X X X pH Meter/Probe Daily Yearly1.2 2.14 X X X X X X X Temperature Controller At Start-up 2x/Year1.3 2.14 X X Rectifier At Start-up N/A
1.4 2.14 X X X X X Wet Analysis N/A
1.5 2.14 X Atomic Absorption (Optional)1.6 2.14 X X X X X X X Filters * N/A * As needed based on pressure.1.7 2.14 X X X Balance 1x/Week Yearly1.8 2.14 X X Coductivity Meter Before Use Yearly1.9 2.14 X X Viscosity Measurement Hourly Monthly1.10 2.14 X Thermocouple N/A 2x/Year
MINIMUM REQUIRED TESTING CAPABILITY2.1 2.14 X X X X X X Salt Spray Cabinet2.2 2.14 X X X X X Water Immersion Tank2.3 2.14 X Environmental Chamber2.4 2.14 X Cure Testing (chemical rubbing)2.5 2.14 X X X X X X Adhesion Testing 2.6 2.14 X X X X X X Thickness Testing2.7 2.14 X X X X X X Microscope (when applicable)2.8 2.14 X Freezer (plastic substrate)2.9 2.14 X Lab Oven
PROCESS TABLE J - EQUIPMENT
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify coater is conforming to customer requirements.
Related CSA Question #
Powder Coat
Calibration Frequency
Phosphate - 3hr min. Paint Lines - Before Run
E-Coat - 1x/Shift min.
Cover PageCover Page Index PageIndex Page
CQI-15 WELDING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet
1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and WeldingSpecialist) or different management system, then these locations shall be considered as separate facilities.
2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
4 Fax number: The fax number of the facility.
5 Number of Welding Employees at this Facility: The number of employees, salaried and hourly, associated with the welding operation at this facility.
6 Captive Welder (Y/N): Enter "Y" if this facility welds components for their own company. Enter"N" if the company does not weld any components for their own company.
7 Commercial Welder (Y/N): Enter "Y" if this facility welds components for companies other thantheir own company. Enter "N" if this facility does not weld any components for other companies.
8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.
9 Date of Previous Assessment: List the date of the previous CQI-15 Special Process: WeldingSystem Assessment of this facility.
10 Type(s) of Welding at this Facility: Place a checkmark to designate the welding process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the WeldingSystem Assessment.
11 Current Quality Certification(s): the welder shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the wleder shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the welder's organization.
14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
CQI-15 WELDING SYSTEM ASSESSMENT
Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and WeldingSpecialist) or different management system, then these locations shall be considered as separate facilities.
Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
Fax number: The fax number of the facility.
Number of Welding Employees at this Facility: The number of employees, salaried and hourly, associated with the welding operation at this facility.
Captive Welder (Y/N): Enter "Y" if this facility welds components for their own company. Enter"N" if the company does not weld any components for their own company.
Commercial Welder (Y/N): Enter "Y" if this facility welds components for companies other thantheir own company. Enter "N" if this facility does not weld any components for other companies.Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.
Date of Previous Assessment: List the date of the previous CQI-15 Special Process: WeldingSystem Assessment of this facility.
Type(s) of Welding at this Facility: Place a checkmark to designate the welding process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the WeldingSystem Assessment.
Current Quality Certification(s): the welder shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the wleder shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the welder's organization.
Cover PageCover Page Index PageIndex Page
Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
Special Process: Welding System Assessment
Facility Name:Address:
Phone Number:
Fax Number:
Number of Welding Employees at this Facility:
Captive Weld Organization (Y/N)
Date of Assessment:
Date of Previous Assessment:
Current Quality Certification(s)
Date of Re-assessment (if necessary):Personnel Contacted:Name Title
0 00 00 00 0
Commercial Weld Organization (Y/N)
Auditors/AssessorsName Company
0000
Number of "Not Satisfactory" Findings
Number of "Needs Immediate Action" Findings
Number of "Fail" Findings in the Job Audit(s)
© 2010 Automotive Industry Action Group (AIAG)
Special Process: Welding System Assessment
Facility Name:Address:
Type(s) of Weld Processing at this Facility:
Process Table A - Arc WeldingArc Stud/Fastener WeldingFlux Cored Arc WeldingGas Metal Arc WeldingSubmerged Arc WeldingShielded Metal Arc Welding
Plasma Arc Welding
Gas Tungsten Arc Welding
Gas Metal Arc Braze Welding
Process Table B - Resistance Welding
Resistance Spot WeldingProjection WeldingResistance Seam Welding
High-frequency Seam WeldingInduction Seam WeldingMash Seam WeldingFlash WeldingProcess Table C - Laser WeldingNd YAG WeldingCO2 WeldingDiode WeldingWire FedProcess Table D - Solid State WeldingInertia Friction Welding
Direct Drive Friction WeldingFriction Stir WeldingFlash Butt WeldingResistance Butt WeldingUltrasonic Welding
Date of Re-assessment (if necessary):
Phone Email
Cover PageCover Page Index PageIndex Page
Phone Email
Special Process: Welding System Assessment
Question Requirements and Guidance
Section 1 - Management Responsibility & Quality Planning
1.1
1.2
1.3
1.4
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violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Question Number
Is there a dedicated and qualified technical welding
person on-site?
To ensure readily available expertise, there shall be a dedicated and qualified welding person on site. This individual shall be one of the following: Degreed Welding Engineer, or equivalent science degree, Certified Welding Inspector from approved internationally recognized body, or person agreed upon between customer and supplier. This person shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and welding knowledge. The qualifications shall include a minimum of 5 years experience in welding operations or a combination of a minimum of 5 years of formal metallurgical education and welding experience.
Is there a responsibility matrix to ensure that all key
management and supervisory functions are performed by
qualified personnel?
The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management and customer at all times.
Do you use only qualified welders (personnel)?
The organization shall provide employee training for all welding operations specific to their job function. All welding employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees were trained; the evidence shall include an assessment of the effectiveness of the training, must prove knowledge of the customer's specific requirements and internal standards, and where appropriate, employee certification, such as for a manual welder. Management and customer shall define the qualification requirements for each function and ongoing or follow-up training shall also be addressed.
How do you maintain welder certification?
Required qualification maintenance. If the welder has not welded in the specific operation in a 6 month time frame, the welder must be requalified to that operation. Based on the welder's quality performance, it must be established when retraining and requalification of the individual must be performed.
1.5
1.6
1.7
1.8
Is set-up practice in compliance with documented
work instructions?
Set-up verification to the procedures (as example: equipment settings, clamping sequence, weld sequence, direction of travel and other process controls) in compliance to documented work instructions.
Does the welding organization perform advanced quality
planning?
The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The welding organization shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Are welding FMEA's up to date and reflecting current
processing?
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key welding process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
Are welding process control plans up to date and reflecting
current processing?
The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls. The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. They shall address all process steps from part receipt to part shipment and identify all equipment used and all essential welding process parameters as defined by the relevant individual process tables or non-essential as agreed upon between supplier and customer. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.
1.9
1.10
1.11
Are all welding related and referenced specifications
current and available? For example: SAE, AIAG, ASTM, ASME, AWS, ISO, General
Motors, Honda, Ford, Toyota and Chrysler.
To ensure all customer requirements are both understood and satisfied, the organization shall have all specifically related welding and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications may include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, ASME, AWS, ISO, General Motors, Honda, Ford, Toyota, and Chrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards/specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify whois responsible for performing these tasks.
Is there a written process specification for all active
processes?
The welding organization shall have written process specifications for all active processes and repair processes which identify all steps of the process including relevant operating parameters. Examples of operating parameters as defined by the relevant process tables. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control.
These process specifications may take the form of work instructions, job card, set-up sheets, or other similar documents.
Has a valid product capability study been performed initially and after process changes?
The organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, and after a major process change of any equipment or parameter. The organization and customer shall define what constitutes a major process change. Initial product capability studies shall be conducted for all welding processes per each process path defined in scope of work and in accordance with customer requirements. In the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to be followed in case capability indices fall outside customer requirements or established ranges.
1.11
1.12
1.13
1.14
1.15
1.16
1.17
Has a valid product capability study been performed initially and after process changes?
Each process path includes all combinations of equipment that are integrated in the performance of a welding process, e.g., weld cell with A and B side fixture feeding another weld cell with A and B side fixture or multiple machines. Capability study techniques shall include boundary sample conditions as defined by the control plan that are robust and meet all customer requirements. Example, any combination of tolerances as defined by Process Tables.
Does the welding organization monitor and analyze data over time, and react to this data?
The analysis of products or processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or essential process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.
Is management reviewing the weld control system at a
frequency determined by the control plan?
Management shall review the weld process control systems. The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the control system shall be documented and recorded in the control plan.
Are internal assessments being completed on an annual
basis, at a minimum, using AIAG WSA?
The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG WSA. Concerns shall be addressed in a timely manner.
Does the Quality Department review, address, and
document customer and internal concerns?
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.
Is there a continual improvement plan applicable
to each process defined in the scope of the assessment?
The welding organization shall define a process for continual improvement for their welding processes identified in the scope of the WSA. The continual improvement process shall be designed to bring about improvements in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.
Does the Quality Manager or designee authorize the
disposition of material from quarantine status?
The Quality Manager or designee is responsible for authorizing and documenting the disposition of quarantined material.
1.18
1.19
1.20
1.21
1.22
1.23
Are there procedures or work instructions available to the
welding personnel that define the welding process?
There shall be procedures or work instructions available to welding personnel covering the welding process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, safety, house-keeping, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.
Is there a preventive maintenance program? Is maintenance data being
utilized to form a predictive maintenance program?
The organization shall have a documented preventive maintenance program for process equipment (as identified by the Process Tables). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.
Has the welding organization developed a critical spare part list and are the parts available
to minimize production disruptions?
The welding organization shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.
How does the organization document and respond to
quality spills, nonconformance, customer
concerns?
Reaction plans are to be followed per the control plan and PFMEA or, in the case of newly indentified issues PFMEA and control plan must be updated to reflect the new failure mode and reaction steps taken.
What is the process deviation requirements of your
customer?
If there are to be changes in process outside of the current control plan and last agreed upon process and parts sign off, do you know what your customer requirements are, have you notified your customer, and do you have customer approval prior to making the change?
Is there a system in place to authorize reprocessing and repair? Is it documented?
The quality management system shall include a documented process for reprocessing and repair that shall include authorization from a customer designated individual. The process shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible. Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary welding modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.
Section 2 - Floor and Material Handling Responsibility
2.1
2.2
2.3
2.4
2.5
2.6
Does the facility ensure that the data entered in the
receiving system matches the information on the customer's
shipping documents?
It is critical that all customer requirements and lot identification be adequately transferred to internal welding documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to captive welding departments. This process refers to receiving and shipping the parts in and out of the welding department.
Is product clearly identified and staged throughout the
welding process?
Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the welding process. Non-welded, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.
Is lot traceability and integrity maintained throughout all
processes?
Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.
Are procedures adequate to prevent movement of non-conforming product into the production system?
The control of suspect or non-conforming product is required to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming hold area shall be clearly designated to maintain segregation of such material.
Are containers free of inappropriate material and
contaminants?
Containers handling customer product shall be free of inappropriate material and contaminants. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming welded parts or inappropriate material contaminate the finished lot.
Is part loading specified, documented and controlled?
Loading parameters shall be specified, documented, and controlled. Examples include part load sequence and clamp sequence.
2.7
2.8
2.9
2.10
Section 3 - Equipment / Facilities/Controls
3.1
3.2
3.3
Is there a containment reaction plan and are
operators trained in the process?
Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the welding process. Evidence shall exist showing disposition and traceability of affected product. Unplanned or emergency downtime greatly raises the risk of improper processing.
Is the handling, storage and packaging adequate to
preserve product quality?
The welder’s loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.Other practices such as stacking of overloaded containers can also increase the risk of part damage.
Are plant cleanliness, housekeeping, environmental
and working conditions conducive to control and
improved quality?
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The welding organization shall evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, contaminants, oil, inadequate plant lighting, fumes, etc.
Are parts free from contaminants that would be detrimental to the quality of
the welding processes, subsequent processes, or the
product?
Parts shall be free from contaminants that are detrimental to the quality of the welding processes, subsequent processes, or the product. If applicable, pre-wash and post-wash parameters shall be monitored and documented.
Are the facilities sufficient for the welding operation?
This could include but is not limited to, facilities capabilities such as safely, environmental regulations/practice, sufficient incoming power (balance and loading), air (sizing, filtering and cleanliness), water, power supply grounding per OEM and regulatory specifications, gas mixing system (equipment and sizing), ventilation, and adequate lighting.
Are the power supplies sufficiently sized?
The power supply should be adequate for the manufacturing process with consideration not limited to output energy, duty cycle, cooling, flow rates and grounding.
Are process equipment calibrations and/or verification
certified, documented, available, and current?
The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables.
3.4
3.5
3.6
Section 4 - TOOLING/FIXTURING
4.1
4.2
4.3
4.4
4.5
Section 5 - PROCESS CONTROLS AND CONFIRMATION
5.1
5.1.1
5.1.2 With over rides or resets, logs must be maintained.
5.1.3 Weld faults audible, visible and line shut down.
Has a preventative maintenance program been
established and documented?
Supplier shall have a preventative maintenance program that is documented and implemented. Refer to Section 1.19 and the applicable Process Tables.
Have the necessary replacement parts and
process consumables been identified and made readily
available?
The replacement parts and process consumables shall be identified, maintained in the appropriate volumes and proper storage. Consumables must be on the customer's approved source list (if applicable). Refer to the applicable Process Tables, Section 2.0 and Section 1.19. This shall be captured in tools such as the set up procedure, PFMEA and Control Plans. It should be included in the layered process audit or other similar type quality review process.
Are the process, equipment, and safety alarm checks
being tested at the required frequency or after any repair
or rebuild?
The welding operation shall have a list of welding process, equipment, and safety alarms. These alarms shall be individually tested at the required frequency as listed in the control plan, and after any repair, process change or rebuild. These checks shall be documented.
Is there a record of the design and set-up of the fixture?
Supplier shall have documentation of the fixture design, that are stored properly and accessible. Proper identification and revision level on the fixture or related to the fixture. Documented fixture set-up (i.e., clamps, pins, locating devices)
Is the positioning of each part being controlled?
A method to detect proper fixture and part position is required for each part, such as the use of proximity switches, optical sensors, mechanical probes, part presence or poke yokes., etc.
Has fixturing/tooling preventative maintenance
program been established?
Supplier shall have a preventative maintenance program that is documented and implemented. Refer to Section 1.18 and the applicable Process Tables. Examples: cleaning, degreasing, and fixturing integrity.
Are the fixture components robust?
Gas, air, sensors, control cables, etc. are adequately protected for the process environment.
Are the tooling components designed for the welding
process?
Fixturing/tooling was developed considering movement, reach, accessibility, tool center point, maintenance, and ergonomics (manual, automatic, and robotics)
Does welding operation include the following?
Identify the process control equipment necessary to monitor, control and provide feedback on all essential process variables as listed below and in the applicable Process Tables.
Logic has been established to effectively identify and address process or equipment faults.
5.1.4
5.1.5 Calibration of meters and system controls.
5.1.6
5.1.7
5.1.8 High/Low limit alarms established by actual data.
5.1.9
5.1.10 Acceptable traceability (sequence/date coding)
5.1.11 All tooling and process changes are documented.
5.1.12
5.1.13 Change over procedure (filler material, fixtures)
5.1.14
5.2
5.3
5.4
5.5
5.6
5.6.1 Cut and etch
5.6.2
5.6.3 Correct number of welds
5.6.4 Weld length/size
5.6.5 Weld location
5.6.6 Non Destructive Testing (NDT)
At weld cycle interrupt, part must not be removed or passed until dispositioned by appropriate personnel.
Inter-locking of previous operations have occurred and quality of parts has been verified before the next operation begins.
Secure backups of all programs and procedures (electronic preferred).
Process variables have been defined and developed by data and shown to be statistically capable.
Documented welding procedures for each weld location and each process variable.
Must have documented start-up and shut-down procedure.
Are process control parameters monitored at established frequencies?
Process control parameters shall be monitored per frequencies established in the control plan. An appropriate person shall verify the process control parameters. Management review is required per Question 1.13.
How does the organization review and react to out of
control/specification parameters?
Are there documented reaction plans with appropriate levels of containment for both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?
How does the organization handle changes to process
control parameters after initial customer approval?
There shall be a hierarchy established for making and approving process changes. Each process should be acted on according to the level of change. Review process changes with your customer.
Are In-Process and Final Tests performed at
established frequencies?
In-Process and Final Tests shall be performed per frequencies in the control plan as agreed upon between the supplier and the customer.
Are weld quality requirements clearly defined per customer
specifications?
Weld quality requirements per internal and customer specifications, such as but not limited to the following testing methodology:
Part location, warping, gap, and dimensional requirements
5.6.7 Spatter, undercut, porosity, discontinuities,…
5.6.8 Weld direction confirmation
5.6.9 Destructive testing
5.6.10 Additional testing
© 2010 Automotive Industry Action Group (AIAG)
Special Process: Welding System Assessment
Assessment
Objective Evidence N/A Satisfactory Not Satisfactory
Section 1 - Management Responsibility & Quality Planning
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Needs Immediate Action
Cover PageCover Page Index PageIndex Page
Section 2 - Floor and Material Handling Responsibility
Section 3 - Equipment / Facilities/Controls
Section 4 - TOOLING/FIXTURING
Section 5 - PROCESS CONTROLS AND CONFIRMATION
Section 6 - Job Audit
Job Identity:Customer:Shop Order Number:Part Number:Part Description:Base Metal Specifications:Filler Metal Specification (if required):Welding Process(es):
Question # Job Audit Question
6.1
6.25.1
6.3Are over rides or resets logs maintained? 5.1.2
6.45.1.3
6.5
6.6
6.7
6.8
6.9
6.105.1.9
6.11
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
RelatedWSA Question #
Has the welding operation identified the process control equipment necessary to monitor, control and provide feedback on all essential process variables as listed in the applicable Process Tables?
1.85.15.2
Has the logic been established to effectively identify and address process or equipment faults?
Are weld faults audible, visible and does the line shut down?
If the weld cycle is interrupted, is the part controlled or contained until dispositioned by appropriate personnel?
2.75.1.4
Are the meters and feed back controls calibrated per established frequencies?
5.1.53.3
If applicable, is there an inter-locking of the previous operation and has the quality of parts been verified?
5.1.6
Are there secure backups of all programs and procedures (electronic preferred)?
5.1.7
Are high/low limit alarms established by actual data.
5.1.85.1.1
Have process variables been defined and developed by data and shown to be statistically capable?
Is there acceptable traceability (sequence/date coding)?
5.1.105.1.11
2.32.7
6.12
6.13
6.14
6.15
6.165.2
6.17
6.18
6.19
6.20
6.20.1 Test Type:
Test Method:
Test Frequency and Quantity:
Specification:
6.20.2 Test Type:
Test Method:
Test Frequency and Quantity:
Specification:
6.20.3 Test Type:
Test Method:
Test Frequency and Quantity:
Specification:
6.20.4 Test Type:
Is there traceability of all process and tooling changes?
4.15.1.11
5.4
Are there documented welding procedures for each weld location and each process variable?
5.1.121.5
1.10
Is there a documented change over procedure (filler material, fixtures)?
1.55.1.13
3.6
Is there a documented start-up and shut-down procedure?
1.51.10
5.1.14
Are process control parameters monitored at established frequencies?
Are there documented reaction plans with appropriate levels of containment to both out of control and out of tolerance process parameters and provide documented evidence that reaction plans are followed?
5.31.215.61.82.7
How does the organization handle changes to process control parameters after initial customer approval and how do you notify your customer?
1.65.4
1.221.16
Are In-Process and Final Tests performed at established frequencies?
1.85.5
Are weld quality requirements clearly defined per customer specifications?
1.95.6
Test Method:
Test Frequency and Quantity:
Specification:
© 2010 Automotive Industry Action Group (AIAG)
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation
Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Cover PageCover Page Index PageIndex Page
Each part may have one or more requirements determined by the welding specification. Parts must meet each requirement. List requirements below and validate.
Item # Category/Process Steps
1.0 1.7, 1.8
A1.1 Arc voltage
A1.2 Amperage
A1.3 Current type (AC/DCEN/DCEP)
A1.4 Wire feed speed
A1.5
A1.6 Stud gun/torch position work angle, travel angle
A1.7 Contact tip-to-work distance
A1.8 Electrode-to-work distance
A1.9 Lift height of stud
A1.10 Fastener coating (determines current type)
A1.11 Plunge control mode force or position
A1.12 Flux classification and depth
A1.13 Flux removal and reclaimation plan
A1.14 Gas flow pre-flow, post-flow, rate and type(s)
A1.15
A1.16 Travel speed
A1.17 Gas nozzle size and type
A1.18 Arc starting parameters
A1.19 Arc end parameters
PROCESS TABLE A- Arc Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.
Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.
Related WSA Question #
Arc welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures
Pulse setting variables specific to the OEM of the welding equipment must be documented and controlled.
Electrode and/or filler metal type, diameter, and classicifacation
A1.20 Wire burnback settings
A1.21 Plunge depth
A1.22 Arc time
A1.23 Fastener geometry per material type
A1.24 Nozzle cleaning and cleaners, replacement
A1.25 Tip changes
A1.26 Wire liners/conduits cleaning and replacing
A1.27 Drive roll changes
A1.28 Wire guide tube change
A1.29 Antispatter Application (spray/dip and equipment)
A1.30 Electrode and stud collet change
A1.31 O rings in gas system maintenance
A1.32 Gas delivery and mixing system
A1.33 Flux delivery systems maintenance
A1.34 Flux removal (screens size and magnetic separators)
A1.35 Electrode sharpening
A1.36 Slag removal
A1.37 Wire dereelers maintenance
A1.38 Wire brake adjustment
A1.39 Integrity of ground system
© 2010 Automotive Industry Action Group (AIAG)
What are your procedures for:
x1: Processes can be used both with and without filler metal.
x2: These welding processes are designated for either gas shielded, self shielded or gasless.
x3: Arc Spot welding applicactions only.
x x x x x
x x x x x x x
x x x x x x x
x x x
x x x
x x x x x x x
x x xü x x
x
x
x
x
x
x x x
x
x x x x
x x x ü x x
x x x
x x x ü x x
x x x x x
PROCESS TABLE A- Arc Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming
X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.
Arc Stud/ Fastener Welding (SW)
Flux-Cored Arc Welding (FCAW)
Gas Metal Arc Welding (GMAW)
Submerged Arc Welding (SAW)
Shielded Metal Arc Welding (SMAW)
Plasma Arc Welding (PAW)
Gas Tungsten Arc Welding (GTAW)
x1 x1
x2 x2
x1 x1
x2 x2
Cover PageCover Page Index PageIndex Page
x x x
x
x
xü ü ü ü ü
ü ü ü ü
ü ü üü ü ü
ü ü ü
ü ü
ü ü
ü ü ü ü ü
x x xü
ü
ü ü
x x xü ü ü
ü ü ü
ü ü ü ü ü ü ü
x3 x3 x3 x3
x2 x2
: These welding processes are designated for either gas shielded, self shielded or gasless.
x
x
x
x
x
x
x
x
x
x
x
x
x
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming
Gas Metal Arc Braze Welding
Index PageIndex Page
x
ü
ü
üü
ü
ü
ü
x
ü
ü
ü
Item # Category/Process Steps
2.0 1.7, 1.8
B2.1 Weld force
B2.2 Clamp force
B2.3 Forge force
B2.4 Forge delay
B2.5 Amperage
B2.6 Voltage
B2.7 Power
B2.8 Frequency
B2.9 Pulsation
B2.10 Squeeze time/cycles
B2.11 Weld time/cycles
B2.12 Hold time/cycles
B2.13 Quench time/cycles
B2.14 Temper time
B2.15 Cool time/cycles
B2.16 Upslope time/cycles
B2.17 Stepper programs
B2.18 Tip/electrode/wheel dressing
B2.19 Weld travel speed
B2.20 Adequate electrode follow up in weld force / distance
B2.21 System cooling-transformers, electrodes, etc.
PROCESS TABLE B- Resistance Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action
Group are registered service marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.
Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.
Related WSA Question #
Resistance welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures
B2.22 Tip/electrode/wheel/coil change frequency
B2.23 Tip/electrode/wheel/coil alignment
B2.24 Electrode selection/type (material type etc.)
B2.25 Electrode geometry
B2.26 Induction coil geometry
B2.27
B2.28 Projection weld geometry and size
*Flash Welding is a Solid State process, however, the process controls most resemble a resistance weld process.Refer to Table D for other requirements on Flash Welding
© 2010 Automotive Industry Action Group (AIAG)
What are your procedures for:
Secondary loop electrical conductors (cables, leaf shunts, etc.) and mechanical joints maintenance
X X X X Xü ü ü
ü ü ü
ü ü
X X X X
X X X X ü
ü ü
X X X X X X X
X X X X
X X X X
X X X X X
X X X X Xü ü ü ü ü ü ü
ü ü ü ü ü ü ü
X X X X
X X X X X X X
X
X X X X X X
X X X X
X X X
X X X X X X X
PROCESS TABLE B- Resistance Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action
Group are registered service marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is
X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.
Resistance Spot Welding (RSW)
Projection Welding (PW)
Resistance Seam Welding (RSEW)
High-Frequency Seam Welding (RSEW-HF)
Induction Seam Welding (RSEW-I)
Mash Seam Welding (RSEW-MS)
Flash Welding* (FW)
Cover PageCover Page Index PageIndex Page
X X X X X X X
X X X X X X Xü ü ü ü ü ü
ü ü ü ü ü ü
ü
ü ü ü ü ü ü ü
ü
*Flash Welding is a Solid State process, however, the process controls most resemble a resistance weld process.
Item # Category/Process Steps
3.0 1.7, 1.8
Equipment
C3.1 Beam quality
C3.2 Optic cleanliness
C3.3 Cross jet or laser knife
C3.4 Beam configuration (split, single)
C3.5 Focal length
C3.6 Beam spot size
C3.7 Gas tube angle/arrangement
C3.8 Optics purge gas (flow and quality)
C3.9 Mirror cleanliness
C3.10 Mirror degradation
C3.11 Beam sharing
C3.12 Split beam
C3.13 Tip changes
C3.14 O rings in gas system
C3.15 Gas nozzle
C3.16 Torch angles
C3.17 Chillers (internal - external)
C3.18 - Flow rate
C3.19 - Water quality
PROCESS TABLE C- Laser Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.
Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.
Related WSA Question #
Welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures
C3.20 - Type of coolant
C3.21 - Additive concentration
C3.22 - Temperature control (rate of change and range)
C3.23 Wire feed system
C3.24 - Wire feed speed
C3.25 - Wire liners/conduits cleaning and replacing
C3.26 - Drive roll changes
C3.27 - Wire guide tube
C3.28 - Wire derealers
C3.29 - Wire brake adjustment
C3.30 - Wire cleaners/wipers
C3.31 - Contact tip to work distance
C3.32 - Wire position to laser focal point
Beam Delivery
C3.33 Direct
C3.34 Fiber
C3.35 - Fiber diameter
C3.36 - Fiber lengths
C3.37 - Bend radius
C3.38 - Condition of fiber
C3.39 - Fiber ends (condition of fiber ends)
C3.40 - Fiber end cooling
C3.41 Mirror
C3.42 - Power loss though the delivery system
C3.43 - Alignment
C3.44 - Cleanliness
C3.45 - Coatings of mirror
C3.46 - Mirror type
C3.47 - Optic and mirror cooling
Process Variables
C3.48 Shielding gas type - flow rate
C3.49
C3.50 Power Output Control
C3.51 Power ramping/program (start, weld, end)
C3.52 Power at the work piece
C3.53 Offset of beam to joint
C3.54 Continuous wave
C3.55 Pulsation
C3.56 Angle of Incidence
C3.57 Focus point
Weld travel speed control (rate of change, and velocity control)
C3.58 Direction of welding (trailing or lead)
C3.59 Beam quality burn-in
C3.60 Power output control calibration
C3.61 Plasma suppression
C3.62 - Monitoring Back scatter for control process
Fixtures/Part
C3.63 - Stability and/or vibration isolation
C3.64 - Articulation system (smoothness of motion and accuracy)
C3.65 Part fit up
C3.66 Seam tracking
C3.67 Edge condition
C3.68 Coatings
© 2010 Automotive Industry Action Group (AIAG)
What are your procedures for controlling:
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X
X X X
X X X
X X X X
X X X X
X
X
X
X
X X X X
X X X X
X X X X
- Laser Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.
X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.
Nd YAG (LBW)
CO2 (LBW)
DIODE (LBW)
With Wire Feed
System
Cover PageCover Page Index PageIndex Page
X X X X
X X X X
X X X X
X
X
X
X
X
X
X
X
X
X
X X
X X X
X X X
X X X
X X X
X X X
X X X
X X X
X X
X X
X X
X X
X X
X X
X X
X X X X
X XX X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X X X X
X Xü ü ü ü
X X X X
X X X Xü ü ü ü
ü ü ü ü
ü ü ü ü
ü ü ü ü
Item # Category/Process Steps
4.0 1.7, 1.8
D4.1 Tolerances on axial alignment
D4.2 Faying surface area
D4.3 Faying surface cleanliness
D4.4 Initial spindal speed
D4.5 Welding spindal speed
D4.6 Spindal torque - to not damage equipment
D4.7 Flywheels; total moment of inertia
D4.8 Spindle clamp pressure
D4.9 Fixture clamp pressure
D4.10 Part stickout
Preheat (First friction phase) if needed
D4.11 -Projection on faying surface
D4.12 -Preheat force
D4.13 -Preheat time or RPM
D4.14
Weld Heat (Second friction phase)
D4.15 -Friction weld force
D4.16 -Friction speed at which forging begins
Forging Stage
D4.17 -Forging speed
D4.18 -Forge force
PROCESS TABLE D - Solid State Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming to the customer's requirements.
Dashes below indicate "not applicable". X indicates an essential variable which shall be documented and controlled.ü indicates that procedure should be reviewed and documented when necessary.
Related WSA Question #
Welding specific essential variables which shall be addressed in the FMEA, control plan and welding procedures
Preheat burnoff length-amount of dimension loss during preheat
D4.19 -Forge time
D4.20 -Forge length if limited upset is used
D4.21 -Forge delay
D4.22 -Upset distance
D4.23 -Upset removal / management
D4.24 -Upset hold time
D4.25 -Upset rate
D4.26 -Friction upset distance and time
D4.27 Brake setting or stopping time dimensions and tolerences
D4.28 Brake force
D4.29 Brake delay prior to upset
D4.30 Final position
D4.31 Postweld heat treatment if needed based on materials joined
D4.32 Protective atmosphere if necessary for the base material
D4.33 Total burnoff-amount of dimension loss during total process
FSW
D4.34 Primary control (position or force)
D4.35 Tool to weld joint alignment during length of travel
Tool
D4.36 -Pin to shoulder ratio
D4.37 -Pin length
D4.38 -Included angle for pin
D4.39 -Included angle for shoulder
D4.40 -Thread on pin surface
D4.41 -Pin material
Plunge Practice
D4.42 -Speed of plunge
D4.43 -Spindal speed during plunge
D4.44 -Preheat dwell time after plunge
D4.45 -Plunge force
Weld
D4.46 -Weld force
D4.47 -Travel speed
D4.48 -Tool tilt angle
D4.49 -Weld spindal speed
Weld termination
D4.50 -Exit motion of tool such as tilt angle rotation
D4.51 -Spindal speed at tool extraction
D4.52 -Dwell at end of travel
FBW RBW
D4.53 Electrode design-eliminate die burns
D4.54 Electrode/Die cleanliness
D4.55 Electrode/Die clamping pressure
D4.56 Part cleanliness and scale removal
D4.57 Part alignment
D4.58 Joint geometry preporation
D4.59 Initial martial stickout or extension beyond electrodes
Preheat
D4.60 -Preheat force
D4.61 -Tap selection
D4.62 -Percent heat
D4.63 -Off time during initial die opening
Initial Flashing
D4.64 -Initial die opening
D4.65 -Initial flashing rate
D4.66 -Type of platten movement (linear or parabolic)
D4.67 -Voltage
D4.68 -Initial flashing distance or time
D4.69 -Percent heat
D4.70 -Tap selection
Flashing
D4.71 -Flashing rate
D4.72 -Type of platten movement (linear or parabolic)
D4.73 -Voltage
D4.74 -Flashing distance or time
D4.75 -Percent heat
D4.76 -Tap selection
Weld Stage 1
D4.77 -Percent heat
D4.78 -Tap selection voltage
D4.79 -Force
D4.80 -Pulsation (on, off and number of pulses)
D4.81 -Off time before stage change
Weld Stage 2 (can be multiple stages with different parameters)
D4.82 -Percent heat
D4.83 -Tap selection voltage
D4.84 -Force
D4.85 -Pulsation (on, off and number of pulses)
Forge/Upset
D4.86 -Forge rate
D4.87 -Forge force
D4.88 -Forge distance / total upset
D4.89 -Upset time
D4.90 -Upset current
D4.91 -Flashing voltage cut off
D4.92 -Flashing removal / management
Post weld heat treatment if needed
D4.93 -Heat treatment clamping distance
D4.94 -Quench time
D4.95 -Tap selection
D4.96 -Precent heat
D4.97 -Temper time
D4.98 Final die opening
Ultrasonic Metal weldD4.99 Tap selection / design of ribbon structure
D4.100 Frequency of power supply for application (40/30/20kHz)
D4.101 Fixture & part design with max dimension deviation and material specsUpset and Monitoring (windowing)
D4.102 Welding-Energy
D4.103 Welding-Time
D4.104 Welding-Amplitude
D4.105 Welding-Force
D4.106 Welding-Current
D4.107 Welding pre Height and travel (compaction)
D4.108 Energy with height compensation
D4.109 Weld Head Cooling
D4.110 Environmental conditions control (i.e., temperature, humidity, dust, etc.)
D4.111 TAP/Die cleanliness
D4.112 TAP/Die clamping pressure
D4.113 Part cleanliness and scale removal
D4.114 Part alignment
© 2010 Automotive Industry Action Group (AIAG)
x1: If required to achieve heat balance. Example thin part to thick part or various hardnesses.
X X X
X X X
X X X
X X X
X
X X X
X
X X X
X X X
X X
X X
X X
X X
X X
X X
- Solid State Welding Processes
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
X indicates an essential variable which shall be documented and controlled. indicates that procedure should be reviewed and documented when necessary.
Inertia Friction Welding (FRW-I)
Direct Drive Friction Welding
(FRW-DD)
Friction Stir
Welding (FSW)
Flash Butt Welding
(FW)
Resistance Butt
Welding (UW)
Ultrasonic Welding
X1 X1
X1 X1
X1 X1
X1
Cover PageCover Page Index PageIndex Page
X
X
X
X
X X
X X
X X
X
X
X
X
X
ü ü ü
ü
XX X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Weld Stage 2 (can be multiple stages with different parameters)
X
X
X
X
X X
X X
X X
X X
X X
X
X X
ü ü
ü ü
ü ü
ü ü
ü ü
X X
üü
Fixture & part design with max dimension deviation and material specs ü
X
X
X
X
X
X
Xü
Environmental conditions control (i.e., temperature, humidity, dust, etc.) üüüüü
: If required to achieve heat balance. Example thin part to thick part or various hardnesses.
CQI-17 SOLDERING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet
1 Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and SolderingSpecialist) or different management system, then these locations shall be considered as separate facilities.
2 Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
3 Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
4 Fax number: The fax number of the facility.
5 Number of Soldering Employees at this Facility: The number of employees, salaried and hourly, associated with the soldering operation at this facility.
6 Captive Solder (Y/N): Enter "Y" if this facility solders components for their own company. Enter"N" if the company does not solder any components for their own company.
7 Commercial Solder (Y/N): Enter "Y" if this facility solders components for companies other thantheir own company. Enter "N" if this facility does not solder any components for other companies.
8 Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.
9 Date of Previous Assessment: List the date of the previous CQI-17 Special Process: SolderingSystem Assessment of this facility.
10 Type(s) of Soldering at this Facility: Place a checkmark to designate the soldering process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the SolderingSystem Assessment.
11 Current Quality Certification(s): the solderer shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
12 Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the solderer shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
13 Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the solderer's organization.
14 Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
15 Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
16 Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
17 Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
CQI-17 SOLDERING SYSTEM ASSESSMENT
Facility Name: Name of the facility being assessed.One form shall be used for each facility. The facility may have several buildings or physical locationsin the same general area. If there is a separate management team (Quality Manager and SolderingSpecialist) or different management system, then these locations shall be considered as separate facilities.
Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.
Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the Operations Manager or Quality Manager shall be used.
Fax number: The fax number of the facility.
Number of Soldering Employees at this Facility: The number of employees, salaried and hourly, associated with the soldering operation at this facility.
Captive Solder (Y/N): Enter "Y" if this facility solders components for their own company. Enter"N" if the company does not solder any components for their own company.
Commercial Solder (Y/N): Enter "Y" if this facility solders components for companies other thantheir own company. Enter "N" if this facility does not solder any components for other companies.Date of Assessment: Enter the date(s) of the assessment. An alphanumeric format shall be usedto avoid confusion with different numeric formats.
Date of Previous Assessment: List the date of the previous CQI-17 Special Process: SolderingSystem Assessment of this facility.
Type(s) of Soldering at this Facility: Place a checkmark to designate the soldering process(es)performed at this facility. This information determines the appropriate Process Table that shall beused during the assessment. Processes not listed on the cover sheet are not part of the SolderingSystem Assessment.
Current Quality Certification(s): the solderer shall list their current quality certifications, e.g.,ISO/TS 16949, ISO 9001-2000. Certifications may be from 3rd party sources or customerquality certifications. If customer quality certification is given, then the year of the last assessment by the customer shall also be given.
Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from the original assessment, then the solderer shall address each item and determine correct action,including root cause analysis and implementation of the corresponding corrective action(s).The date of the re-assignment shall be given here, and the appropriate Question(s) from Sections1 - 3, in the original assessment, shall be modified to reflect that the evidence, relating to the implementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.
Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the solderer's organization.
Cover PageCover Page Index PageIndex Page
Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).
Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.
Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.
Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.
Special Process: Soldering System Assessment
Facility Name:Address
Phone NumberFax Number
Number of Soldering Employees at this Facility:
Captive Soldering Organization (Y/N)
Commercial Soldering Organization (Y/N)
Current Quality Certification(s)
Date of Re-assessment (if necessary):Personnel Contacted:Name Title
0 00 00 00 0
Auditors/AssessorsName Company
0000
Number of "Not Satisfactory" Findings
Date of Assessment:
Date of Previous Assessment:
Number of "Needs Immediate Action" Findings
Number of "Fail" Findings in the Job Audit(s)
© 2010 Automortive Industry Action Group (AIAG)
Special Process: Soldering System Assessment
Address
Type(s) of Soldering at this Facility:Process Table A - Process Table K -
Process Table B - Process Table L -
Process Table C - Process Table M -
Process Table D - Process Table N -
Process Table E - Process Table O -
Process Table F - Process Table P -
Process Table G - Process Table Q -
Process Table H - Process Table R -
Process Table I - Process Table S -
Process Table J -
Personnel Contacted:Phone Email
Auditors/AssessorsPhone Email
Cover PageCover Page Index PageIndex Page
Special Process: Soldering Process Assessment (General Facility Overview)
Question Requirements and Guidance
Section 1 - Management Responsibility and Quality Planning
1.1
1.2
1.3
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group
are registered service marks of the Automotive Industry Action Group.
Question Number
Is there a dedicated and qualified soldering expert on-
site?
To ensure readily available expertise, there shall be a dedicated and qualified soldering expert on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and soldering knowledge. The qualifications shall include a minimum of 5 years experience in soldering operations or a combination of a minimum of 5 years of formal metallurgical education and soldering experience.
Does the soldering organization perform
advanced quality planning?
The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The soldering organization shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.
Are soldering FMEA's up to date and reflecting current
processing?
The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key soldering process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.
1.4
1.5
Are soldering process control plans up to date and reflecting
current processing?
The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key solder process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables.
Are all soldering related and referenced specifications current and available? For example: IPC, SAE, AIAG, ASTM, General Motors, Honda, Ford, and Chrysler.
To ensure all customer requirements are both understood and satisfied, the organization shall have all related solder and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by IPC, SAE, AIAG, ASTM, General Motors, Honda, Ford, and Chrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards / specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.
1.6
1.7
1.8
Is there a written process specification for all active
processes?
The solder organization shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, atmosphere or gas flow settings, belt speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control.
These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.
Has a valid process capability study been performed initially and after process equipment has been relocated, or had a
major rebuild?
To demonstrate each process is capable of yielding acceptable product the organization shall perform process capability studies for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial process capability studies shall be conducted for all solder processes per manufacturing line defined in scope of work & in accordance with customer requirements. A manufacturing line may include a combination of equipment that is integrated in the performance of a solder process, e.g., printing, placement, and reflow. Capability study techniques shall be appropriate for the solder product characteristics, e.g., paste height and thermal profiling. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.
Does the solder organization collect and analyze data over time, and react to this data?
The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.
1.9
1.10
1.11
1.12
1.13
1.14
Is management reviewing the soldering process data every
24 hours?
Management shall review the soldering process data at intervals not to exceed 24 hours. The soldering process data includes but is not limited to thermal profiles, SPC, set up sheets and maintenance logs, through-put, etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the soldering process data shall be documented and this requirement also applies to computerized data.
Are internal assessments being completed on an annual
basis, at a minimum, using AIAG SSA?
The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG SSA.
Is there a system in place to authorize rework or repair and
is it documented?
The quality management system shall include a documented process for rework and repair that shall include authorization from a designated individual, a recognized team of experts, or customer requirement. The rework and repair procedures shall describe product characteristics for which rework and repair is allowed as well as those characteristics for which rework is not permissible.Any rework or repair activity shall require a processing control sheet issued by qualified technical personnel denoting the necessary solder rework or repair. Records shall clearly indicate when and how any material has been reworked or repair. Repaired parts shall meet inspection standards, and must be verified by a secondary process such as in-circuit test.
Does the Quality Department review, address, and
document customer and internal concerns?
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.
Is there a continual improvement plan applicable
to each process defined in the scope of the assessment?
The solder organization shall define a process for continual improvement for each solder process identified in the scope of the SSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.
Does the Quality Manager or designee authorize the
disposition of material from quarantine status?
The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material, such as components that are out of tolerance.
1.15
1.16
1.17
1.18
Are there procedures or work instructions available to the solder personnel that define
the soldering process?
There shall be procedures or work instructions available to soldering personnel covering the soldering process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.
Is management providing employee training for
soldering?
The organization shall provide employee training for all soldering operations. All employees associated with the soldering process, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.
Is there a responsibility matrix to ensure that all key
management and supervisory functions are performed by
qualified personnel?
The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.
Is there a preventive maintenance program? Is maintenance data being
utilized to form a predictive maintenance program?
The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization. Maintenance data shall be collected and analyzed as part of a predictive maintenance program.
1.19
Section 2 - Floor and Material Handling Responsibility
2.1
2.2
2.3
2.4
Has the soldering organization developed a
critical spare part list and are the parts available to minimize
production disruptions?
The soldering organization shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.
Does the facility ensure that the data entered in the receiving system matches the information on the customer's shipping documents?
Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. The facility shall have a detailed process in place to resolve receiving discrepancies.
Is product clearly identified and staged throughout the manufacturing soldering process?
Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the soldering process. Unsoldered product, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.
Is lot traceability and integrity maintained throughout all processes?
Out-going lot(s) shall be traceable to the incoming lot(s). The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.Traceability should include bulk packed components used for manual insertion processes.
Are procedures adequate to prevent movement of non-conforming product/material into the production system?
The control of suspect or non-conforming product/material is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification and tracking of material flow in and out of hold area. Non-conforming hold area shall be clearly designated to maintain segregation of such material. The soldering organization shall have documented procedures to identify and segregate improperly soldered parts for each process/equipment resulting from equipment failures/e-stop/loss of power.
2.6
2.7
2.8
2.9
2.10
2.11
Are containers free of inappropriate material?
Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming soldered parts or inappropriate material contaminate the finished lot.
Is part loading specified, documented and controlled?
Loading parameters shall be specified, documented and controlled. Examples include parts per rack and load size.
Are operators trained in material handling, containment action and product segregation in the event of an equipment emergency including power failure?
Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.
Is the handling, storage and packaging adequate to preserve product quality?
The soldering organization loading/unloading systems, in process handling and shipping process shall be assessed for risk of part damage or other quality concerns for proper ESD prevention and detection (example proper operator ESD protection, work station and storage grounding). Also all material storage must meet supplier recommendation (example humidity, temperature and expiration date).
Are plant cleanliness, housekeeping, environmental and safe working conditions conducive to control and improved quality?
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The soldering organization shall evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for the following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes, temperature and humidity controlled per customer expectation.
Are process control parameters monitored per frequencies specified in Process Tables?
Process control parameters shall be monitored per frequencies specified in Process Tables. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log.
2.12
2.13
2.14
© 2010 Automortive Industry Action Group (AIAG)
Are out of control/specification parameters reviewed and reacted to?
Are there documented reaction plans to both out of control and out of tolerance process parameters? Is there documented evidence that reaction plans are followed?
Are In-Process / Final Test Frequencies performed as specified in Process Tables?
In-Process / Final Test Frequencies shall be performed as specified for critical/function characteristics identified in Process Tables. Refer to Process Tables.
Is product test equipment verified?
Test equipment shall be verified/calibrated per applicable customer specific standard or per an applicable consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.
Refer to Process Tables for frequency of checks.
Special Process: Soldering Process Assessment (General Facility Overview)
Assessment
Objective Evidence N/A Satisfactory
Section 1 - Management Responsibility and Quality Planning
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are registered service marks of the Automotive Industry Action Group.
Not Satisfactory
Needs Immediate Action
Cover PageCover Page Index PageIndex Page
Section 2 - Floor and Material Handling Responsibility
Special Process: Soldering Process Assessment (Equipment)
Question
Section 3 - Equipment
3.1
3.2
3.3
3.4
3.5
3.6
3.7
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil
penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
Question Number
Requirements and Guidance
Does each stage of the soldering operation have proper process controls?
Refer to Process Tables for requirements.
Are process and testing equipment calibrations and/or verification certified, posted, and current?
A system shall be used by the soldering facility to track calibration dates of equipment. This system will typically be a computerized tracking system or other notification system. Test equipment shall be verified/calibrated per applicable customer specific standard or consensus standard, e.g., ASTM, SAE, ISO, NIST, etc. Verification/calibration results shall be internally reviewed, approved and documented.
Are PCB magazines, screen printer stencils, solder pallets, and other tooling maintained?
Supplier shall have preventative maintenance system that is documented and implemented.
Are thermal profile requirements of soldering operations being monitored?
Supplier shall have adequate temperature controls ensuring that PCB assemblies are only exposed to temperatures within the thermal requirements of components.
For re-flow ovens and preheating zones for wave soldering, are temperature monitoring devices checked and/or replaced regularly?
Supplier shall have preventative maintenance system that is documented and implemented.
Do you have a process to monitor your regulatory requirements and safety of your employees?
Supplier shall have implemented and documented evidence of regulatory requirements and safety.
Is manual soldering and/or re-work equipment calibrated?
Supplier shall have set-up parameters and calibration routines documented and established.
3.8
3.9
Is there post soldering inspection station?
Supplier shall have inspection method to evaluate solder quality and feedback to previous process.
Are ESD or EOS equipment standards established?
All equipment shall be properly grounded.
© 2010 Automortive Industry Action Group (AIAG)
Special Process: Soldering Process Assessment (Equipment)
Assessment
Objective Evidence N/A Satisfactory Not Satisfactory
Section 3 - Equipment
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil
penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
Needs Immediate Action
Cover PageCover Page Index PageIndex Page
Section 4 - Job Audit
This section includes final product and final product assembly and packaging
Job Identity:Customer:
Shop Order Number:Part Number:
Part Description:Material:
Soldering Requirements:
Job Audit Question
4.1
4.2 1.5
4.3
4.4
4.5
4.6
4.7
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive
Industry Action Group are registered service marks of the Automotive Industry Action Group.
Question #
RelatedSSA Question #
Customer or Internal Requirement
Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?
1.21.31.4
1.17
Does the solder organization have the proper customer specifications for the part?
Does the soldering organization have a confirmation method to ensure correct parts and components are installed per customer requirements?
1.62.1
Is material identification (part numbers, lot numbers, contract numbers, etc.) and process sequencing (repair, rework, etc.) traceable to the part throughout the soldering process?
2.22.32.4
Is there documented evidence of a material certification with final inspection?
Are final packaging requirements indentified per customer specifications?
1.62.72.9
Is the proper procedure or process specification used for the soldering process? Refer to Process Tables for specific parameters. List parameters that were verified in this audit in the spaces provided below.
1.51.62.1
2.112.13
4.8 2.13
Functional?
Dimensional?
Acceptability?
4.8.1 Requirement: Functional TestTest Method:Test frequency or quantity:Selection of samples:Specification:
4.8.2
Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.3
Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.4 Requirement: Illumination TestTest Method:Test frequency or quantity:Selection of samples:Specification:
4.8.5 Requirement: In-Circuit TestTest Method:Test frequency or quantity:Selection of samples:Specification:
4.8.6
Test Method:Test frequency or quantity:Selection of samples:Specification:
Note: Section 4.8.7 - 4.8.12 Reserved for Auditor Observations4.8.7 Requirement:
Test Method:Test frequency or quantity:Selection of samples:
What are the product inspection requirements?
Each part may have one or more requirements determined by the soldering specification. Parts must meet each requirement. List each requirement below and validate.
Requirement: Dimensional Requirements
Requirement: Environmental Test
Requirement: Conformal Coating Conformation
Specification:4.8.8 Requirement:
Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.9 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.10 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.11 Requirement: Test Method:Test frequency or quantity:Selection of samples:Specification:
4.8.12 Requirement:Test Method:Test frequency or quantity:Selection of samples:Specification:
Operator or Inspector Responsibilities
4.9
4.10 2.9
4.11
4.12
4.13
4.14
4.15 1.17
Were appropriate process steps signed off?
1.42.22.3
2.11
Are ESD preventive methods applied (i.e., operator apparel) and functionally verified?
Were all inspection steps, as documented in the control plan performed?
1.21.4
Were steps/operations performed that were not documented in the control plan?
1.21.41.6
If additional steps were performed, were they authorized?
1.21.41.6
1.111.17
If the order was certified, did the certification accurately reflect the process performed?
2.112.13
Was the certification signed by an authorized individual?
4.16 2.6
Packaging Requirements
4.17 2.9
4.18 2.9
Shipping Requirements
4.19 2.3
4.20
© 2010 Automortive Industry Action Group (AIAG)
Are the parts and containers free of foreign objects or contamination?
Are packaging requirements identified?
Are parts packaged to minimize mixed parts (parts packed over height of container)?
Were the parts properly identified?
Were the containers properly labeled?
2.32.9
Actual Condition (Objective Evidence)
N/A
N/A
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive
Industry Action Group are registered service marks of the Automotive Industry Action Group.
Job (Shop) Order or Reference Documentation Requirement
Pass / Fail / N/A
Cover PageCover Page Index PageIndex Page
Each part may have one or more requirements determined by the soldering specification. Parts must meet each requirement. List each requirement below and validate.
Operator or Inspector Responsibilities
ITEM # Category/Process Steps Control
1.0
1.1 1.6 Lint Free Cloth Per Spec
1.2 Replacement Frequency Per Control Plan
1.3 1.6 Proper Cleaning Area Per Product Spec
1.4 1.16 Proper Operator Handling Operator Training
2.0 Material Handling
2.1
2.2-2.9
2.1.1 Correct Material Bar Code or Manual
2.1.2 Expiration Date/Lot Control Bar Code or Manual
2.1.3 Properly Mixed Manual
2.1.4 Stabilize to Operation Temperature Bar Code or Manual
2.1.5 Open Container Disposition Bar Code / Check list
2.1.6 Excess solder paste run-out management
2.2
2.2.1 Correct Material Bar Code or Manual
2.2.2 Expiration Date/Lot Control Bar Code or Manual
2.2.3 Environmental Control (exposure) Bar Code or Manual
2.2.4 Contamination Control Work Instruction
2.2.5 Orientation Automatic or Manual
3.0
3.0.1 1.18 Preventive Maintenance (PM) Cleaning PM schedule
3.0.2 Stencil separation speed Automatic
PROCESS TABLE A - Solder Paste Printing
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Printed Wiring Board Cleaning (Dry Wipe)
Paste:Size,Volume,Container:Paste Supplier:
Manual remix / discard
Printed Wiring Board (PWB)Board Supplier:
1.42.112.12
Solder Paste EquipmentType:Equipment Supplier:
3.1
3.1.1 Correct Stencil Bar Code or Manual
3.1.2
3.1.3
3.1.4 3.3 Life Cycle Date Bar Code or Manual
3.1.5 Stencil Alignment Accuracy to Machine Automatic or Manual
3.2 PWB Registration to Stencil
3.2.1 Proper Alignment Automatic
3.2.2 PWB Securing Automatic
3.3
3.3.1 1.6 Squeegee Material Compatibility with Solder Past Design Spec
3.3.2 Correct Squeegee Manual
3.3.3 In process (underside wipe) cleaning Manual or Automatic
3.3.4 Pressure of Squeegee Manual or Automatic
3.3.5 Angle of Squeegee Manual or Automatic
3.3.6 Squeegee Speed Manual or Automatic
3.3.7 Squeegee Stroke Manual or Automatic
3.3.8 1.18 Preventive Maintenance Cleaning/Replace PM schedule
3.4 Pro Flow Cartridge
3.4.1 Solder Flow Pressure Automatic
3.4.2 Correct Cartridge (Pb or Pb Free) Bar Code or Manual
3.4.3 Angle of Cartridge Manual or Automatic
3.4.4 Cartridge Speed Manual or Automatic
3.4.5 Cartridge Stroke Manual or Automatic
3.4.6 1.18 Preventive Maintenance Cleaning PM schedule
4.0 Post Print Inspection
4.1 Method Manual or Automatic
4.2 Frequency Manual
4.3 Reaction of Defects Per Process Controls
Stencil ControlSupplier:Manufacturing Method:Thickness:
In process Bottom Side CleaningType of Cleaning Method:Chemical(s) Used:Frequency:
Automatic or Manual
1.183.3
Preventive Maintenance CleaningType:Chemical(s) Used:Frequency:Confirmation method:
Automatic or Manual
SqueegeeType:Shape:Hardness:Material:
1.42.112.12
4.4 1.6 Proper solder paste height Per Product Spec
4.5 1.6 Proper solder pad coverage Per Product Spec
5.0 Abnormal Condition Reaction
5.1 2.8 Power failure reaction plan Control plan
5.2 2.8 Emergency-stop reaction plan Control plan
5.3 2.8 Part jam reaction plan Control plan
5.4 2.8 Drop part reaction plan Control plan
5.5 2.8 In-Process Delay Reaction Plan Control plan
5.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Quality Audit
Quality Audit
Operator Certification
Continuous
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Lot (first and last piece)
Lot (first and last piece)
Lot
Every Piece
Every Piece
PM Completion Report
Continuous
- Solder Paste Printing
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Every Change Over
Continuous
Start up or Change Over
Continuous
Continuous
Design Review
1/shift or Change Over
Per Control Plan
1/shift or Change Over
1/shift or Change Over
1/shift or Change Over
1/shift or Change Over
PM Completion Report
1/shift or Change Over
1/shift or Change Over
1/shift or Change Over
1/shift or Change Over
1/shift or Change Over
PM Completion Report
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Post Print Inspection
1.1 Manual
1.1.1 1.15, 1.16 Proper Operator training Operator Certification
1.1.2 Boundary Sample Available Good and Bad
1.1.3 Proper Magnification for pitch size Per IPC A 610
1.1.4 Proper illumination at inspection station Per IES
1.1.5 Frequency of sampling
1.2 Automatic
1.2.1 1.7 CPK
1.2.2 1.7 Boundary Sample Available
1.2.3 Calibration or verification method set Per control plan
1.2.4 Non-conforming material disposition
2.0 Post Component Placement
2.1 Automatic Vision System:
2.1.1 Calibration Standard Available
2.1.2 Part Present Yes/No
2.1.3 1.6 Orientation Per Specification
2.1.4 1.6 Polarity Per Specification
2.1.5 1.6 Skew Angle Per Specification
2.1.6 1.6 Off-centered Per Specification
2.1.7 1.6 Raised Per Specification
PROCESS TABLE B - InspectionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
2.112.13
Per Customer Requirement
Per Customer Requirement
Good and Bad sample run at change-over and beginning of shift
1.142.4
Per Customer Requirement
1.42.112.12
Per manufacture recommendation
2.2 Manual Inspection:
2.2.1 1.15, 1.16 Proper Operator training Operator Certification
2.2.2 Good and Bad
2.2.3 Proper Magnification for pitch size Per IPC A 610
2.2.4 Proper illumination at inspection station
2.2.5 Frequency of sampling Per control plan
2.2.6 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20
2.3 Non-conforming material disposition Per control plan
3.0 Post Reflow Inspection
3.1 Automatic Optical Inspection (AOI)
3.1.1 1.6 Solder volumes Per Specification
3.1.2 1.6 Solder ball Per Specification
3.1.3 1.6 Solder bridge Per Specification
3.1.4 1.6 Solder skip Per Specification
3.1.5 1.6 Part present Per Specification
3.1.6 1.6 Component accuracy to solder pads Per Specification
3.1.7 1.6 Tombstoning Per Specification
3.1.8 1.6 Billboarding Per Specification
3.1.9 1.6 Lifted part Per Specification
3.1.10 1.6 Good/Bad Samples Used Per Specification
3.2 X-ray (Recommended for BGA/Flip chip)
3.2.1 1.6 Solder volumes Per Specification
3.2.2 1.6 Solder ball Per Specification
3.2.3 1.6 Solder bridge Per Specification
3.2.4 1.6 Solder skip Per Specification
3.2.5 1.6 Part present Per Specification
3.2.6 1.6 Component accuracy to solder pads Per Specification
3.2.7 1.6 Tombstoning Per Specification
3.2.8 1.6 Billboarding Per Specification
3.2.9 1.6 Lifted part Per Specification
3.2.10 1.6 Void detection Per Specification
3.2.11 1.6 Good/Bad Samples Used Per Specification
3.3 Manual Inspection
3.3.1 1.6 Solder volumes Per Specification
3.3.2 1.6 Solder ball Per Specification
Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present)
Per IES (Illumination Engineering Standard)
1.142.4
1.42.112.123.8
3.3.3 1.6 Solder bridge Per Specification
3.3.4 1.6 Solder skip Per Specification
3.3.5 1.6 Part present Per Specification
3.3.6 1.6 Component accuracy to solder pads Per Specification
3.3.7 1.6 Tombstoning Per Specification
3.3.8 1.6 Billboarding Per Specification
3.3.9 1.6 Lifted part Per Specification
3.3.10 1.6 Void detection Per Specification
3.3.11 1.15, 1.16 Proper Operator training Operator Certification
3.3.12 Good and Bad
3.3.13 Proper Magnification for pitch size Per IPC A 610
3.3.14 Proper illumination at inspection station
3.3.15 Frequency of sampling Per control plan
3.3.16 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20
3.3.17 1.6 Blow hole detection Per Specification
3.3.18 1.6 Confirmation of jig removal Per Specification
3.4 Non-conforming material disposition Per control plan
4.0 Post Wave/Selective Solder Inspection
4.1 Automatic Optical Inspection (AOI)
4.1.1 1.6 Solder volumes Per Specification
4.1.2 1.6 Solder ball Per Specification
4.1.3 1.6 Solder bridge Per Specification
4.1.4 1.6 Solder skip Per Specification
4.1.5 1.6 Part present Per Specification
4.1.6 1.6 Component accuracy to solder pads Per Specification
4.1.7 1.6 Tombstoning Per Specification
4.1.8 1.6 Billboarding Per Specification
4.1.9 1.6 SMT Glue on pad Per Specification
4.1.10 1.6 Lifted part Per Specification
4.1.11 1.6 Excess Flux/flux residue Per Specification
4.1.12 1.6 Proper polarity Per Specification
4.1.13 1.6 Icicling Per Specification
4.1.14 1.6 Good/Bad Samples Used Per Specification
4.2 X-ray
4.2.1 1.6 Solder volumes Per Specification
Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present)
Per IES (Illumination Engineering Standard)
2.112.13
1.142.4
1.42.112.123.8
4.2.2 1.6 Solder ball Per Specification
4.2.3 1.6 Solder bridge Per Specification
4.2.4 1.6 Solder skip Per Specification
4.2.5 1.6 Part present Per Specification
4.2.6 1.6 Component accuracy to solder pads Per Specification
4.2.7 1.6 Tombstoning Per Specification
4.2.8 1.6 Billboarding Per Specification
4.2.9 1.6 Lifted part Per Specification
4.2.10 1.6 Void detection Per Specification
4.2.11 1.6 Icicling Per Specification
4.2.12 1.6 Good/Bad Samples Used Per Specification
4.3 Manual Inspection
4.3.1 1.6 Solder volumes Per Specification
4.3.2 1.6 Solder ball Per Specification
4.3.3 1.6 Solder bridge Per Specification
4.3.4 1.6 Solder skip Per Specification
4.3.5 1.6 Part present Per Specification
4.3.6 1.6 Component accuracy to solder pads Per Specification
4.3.7 1.6 Tombstoning Per Specification
4.3.8 1.6 Billboarding Per Specification
4.3.9 1.6 Lifted part Per Specification
4.3.10 1.6 Void detection Per Specification
4.3.11 1.16 Proper Operator training Operator Certification
4.3.12 Good and Bad
4.3.13 Proper Magnification for pitch size
4.3.14 Proper illumination at inspection station
4.3.15 2.13 Frequency of sampling Per control plan
4.3.16 3.9 Proper ESD protection (work surface and operator) Per ANSI S20.20
4.3.17 Blow hole detection
4.3.18 1.6 Icicling Per Specification
4.3.19 1.6 Excess Flux/flux residue Per Specification
4.3.20 1.6 SMT Glue on pad Per Specification
4.3.21 1.6 Confirmation of jig removal Per Specification
Boundary Sample (e.g., orientation, polarity, skew angle, off-centered, raised, and part present) as needed.
Per IPC A 610 or organizations internal requirements
Per IES (Illumination Engineering Standard) or organizations internal requirements
4.3.22 1.6 No foreign material Per Specification
4.3.23 1.6 Trace delamination Per Specification
4.3.24 1.6 Solder mask degradation Per Specification
4.4 Non-conforming material deposition Per control plan
© 2010 Automortive Industry Action Group (AIAG)
1.142.4
Monitoring Auditor Notes
Annual Certification
Calibration Certification
Annual Certification
Set-up
Check-sheet
Continuous
Calibration Certification
Calibration Certification
Continuous
Calibration Certification
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
- InspectionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Annual Certification
Calibration Certification
Annual Certification
Set-up
Check-sheet
Continuous
Continuous
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Annual Certification
Calibration Certification
Annual Certification
Set-up
Check-sheet
Continuous
Per Control Plan
Per Control Plan
Continuous
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Annual Certification
Calibration Certification
Annual Certification
Set-up
Check-sheet
Continuous
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Per Control Plan
Continuous
ITEM # Category/Process Steps Control
1.0 Cassette/Feeder Loading
1.1 Manual Control
1.1.1 1.15, 1.16 Correct loading Operator Training
1.1.2 3.9 ESD Control Per ANSI S20.20
1.1.3 Correct Part per Feeder Location Set-up Sheet
1.1.4 Operator/Traceability Control Check Sheet
1.1.5 Check Sheet
1.1.6 Humidity (MSD) Control
1.2 Automatic Control
1.2.1 1.15, 1.16 Correct loading Operator Training
1.2.2 3.9 ESD Control Per ANSI S20.20
1.2.3 Correct Part per Feeder Location Bar Code and BOM
1.2.4 Operator/Traceability Control Bar Code Scan
1.2.5
1.2.6 Humidity (MSD) Control Per control plan
2.0 Splicing
2.1 1.15, 1.16 Correct Splicing Operator Training
2.2 3.9 ESD Control Per ANSI S20.20
2.3 1.6 Correct Orientation Per Machine Spec
2.4 Traceability Control
2.5 Humidity Control Per control plan
2.6 1.6 Correct Tape Per Spec
PROCESS TABLE C - Surface Mount Device PlacementThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Component supply management (part shortage prevention)
1.62.10
Per Manufacturer Spec
Component supply management (part shortage prevention)
Machine Programming (Placement Count)
1.62.10
1.42.112.12
Check Sheet/Bar Code
1.62.10
2.7 Correct Splice Operator Training
3.0 Placement Nozzles
3.1 Manual Operation
3.1.1 1.15, 1.16 Correct nozzle selection Operator Training
3.1.2 Vacuum testing Per check sheet
3.1.3 Correct placement stroke & force Per set up sheet
3.1.4 Trigger for First Pass Yield (FPY) Maintenance Per control plan
3.2 Automatic Operation
3.2.1 1.15, 1.16 Correct magazine carrousel loading Operator Training
3.2.2 Correct placement program Per control plan
3.2.3 Initial nozzle vacuum confirmation Per program
3.2.4 Trigger for FPY Maintenance Per control plan
4.0 Vision System
4.1 1.15, 1.16 Proper set up Operator Training
4.2 Per control plan
4.3 1.6 Proper focusing Per product spec
4.4 Proper illumination Per requirement
4.5 Correct operation Per golden sample
4.6 Calibration Per NIST
5.0 Bottom Side Placement
5.1 Must adhered to Items 1.0 - 4.6 above
5.2 Board flex (if top side soldered) Per IPC-A-610
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
1.42.112.12
Proper inspection criteria (placement accuracy, polarity, rotation/skewing)
1.42.112.12
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Per Training Plan
Continuous
Supervisor Audit
100%
Per Control Plan
Per Control Plan
Per Training Plan
Continuous
100%
100%
Continuous
Continuous
Per Training Plan
Continuous
100%
100%
Continuous
100%
- Surface Mount Device PlacementThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Per Training Plan
Per Training Plan
Per change over
Per change over
100%
Per Training Plan
Per change over
100%
100%
Per training plan
100%
100%
100%
Per Control Plan
Per Control Plan
Process Set-up
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Reflow ovens
1.1 3.4 Temperature controller Automatic
1.1.1 3.4 Lead Solder Correct Profile
1.1.2 3.4 Lead Free Solder Correct Profile
1.2 1.18 Heating element Proper PM
1.3 Atmosphere control Automatic
1.3.1 Ventilation Automatic
1.3.2 Nitrogen supply system (if used) Automatic
1.3.3 Oxygen monitoring system (if used) Automatic
1.4 Conveyer width control Per set-up
1.5 Conveyer speed control
1.6 Conveyer infeed cover In place
1.7 3.5 M.O.L.E. / Surveyor
1.7.1 3.5 Thermal couple board placement
1.7.2 3.5 K.I.C. system (if used) Automatic
1.7.3 Profile confirmation verification Per control plan
1.7.4 Process Window (PWI)/Capability Index Per control plan
1.8 3.9 ESD Control Per ANSI S20.20
1.9 Lead/Lead free changeovers Proper oven cleaning
2.0 Loading
2.1 Correct Orientation
2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
PROCESS TABLE D - Reflow Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
Based on board layout
3.43.5
3.43.5
1.42.112.12
Automatic/operator training
2.3 Correct Spacing
2.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training
3.0 Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Cooling/Ion Blowers
3.3.1 Filters presence Per control plan
3.3.2 Proper location on conveyor Per spec/set-up
3.3.3 Blower/ionizer power-on indicator Per control plan
3.4 3.3 Magazines / Unloading racks
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.5 1.14 Written policy
4.0 Component Compatibility
4.1 1.6 Components compatible with temperature profile Component Spec
4.2 1.6 Components compatible with solder Component Spec
5.0 Board Twist Control
5.1 Maximum diagonal twist meets standard
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Automatic/operator training
1.42.112.12
Correct loading sequence for contamination control (top down)
Rejected / inspected part returned to production line and inserted at the removal point.
1.42.112.12
1.42.112.12
Per IPC-TM-650, Section 2.4.22
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Continuous
Continuous
Continuous
Per control plan
Continuous
Continuous
Per control plan
Continuous
Per control plan
Per control plan
Continuous
Continuous
Continuous
- Reflow Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Per control plan/changeover
Cover PageCover Page Index PageIndex Page
Continuous
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Continuous
Continuous
Continuous
Continuous
Control Plan
Design Review
Design Review
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Per Preventative Maintenance
Changeover/profile modification
ITEM # Category/Process Steps Control
1.0
1.1 Correct Material Bar Code or Manual
1.2 Expiration Date/Lot Control Bar Code or Manual
1.3 Properly Mixed Manual
1.4 Stabilize to Operation Temperature Bar Code or Manual
1.5 Open Container Disposition Control plan
2.0 Glue Dispensing Equipment
2.1 Pin Transfer:
2.1.1 PWB Registration to Equipment Automatic
2.1.2 PWB Securing Automatic
2.1.3 1.18 Preventive Maintenance PM schedule
2.1.4 Stabilization and control of glue reservoir Automatic/Manual
2.2
2.2.1 PWB Registration to Equipment Automatic
2.2.2 PWB Securing Automatic
2.2.3 3.3 Correct Stencil Bar Code or Manual
2.3
2.3.1 Type of Cleaning Method Automatic or Manual
2.3.2 Frequency Automatic or Manual
2.4 1.18 PM schedule
2.5 Life Cycle Date Bar Code or Manual
2.6 Stencil Alignment Accuracy to Machine Automatic or Manual
2.7 Syringe:
2.7.1 PWB Registration to Equipment Automatic
PROCESS TABLE E - Glue Dispensing
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Glue:Supplier:Size, Volume, Container:
1.42.112.12
Screen Printing:Stencil Supplier:
In-process Bottom Side Cleaning:Chemical(s) Used:
Preventive Maintenance CleaningChemical(s) Used:Methods Used:
2.7.2 PWB Securing Automatic
2.7.3 1.18 PM schedule
3.0
3.1 3.4 Correct Thermal Profile Automatic or Manual
3.2 Conveyer Speed Per Control Plan
3.3 Rail Width Per Control Plan
4.0 Post Glue Inspection
4.1 Glue Volume Per Control Plan
4.2 Glue Placement Per Control Plan
4.3 Verify Curing is Complete Per Control Plan
4.4 Glue Contamination on Component Pad Per Control Plan
5.0 Abnormal Condition Reaction
5.1 2.8 Power failure reaction plan Control plan
5.2 2.8 Emergency-stop reaction plan Control plan
5.3 2.8 Part jam reaction plan Control plan
5.4 2.8 Drop part reaction plan Control plan
5.5 2.8 In Process Delay Reaction Plan Control plan
5.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Preventive Maintenance CleaningChemical(s) Used:Method Used:
1.42.112.12
Glue Curing ProcessEquipment type:
1.42.112.12
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Every Container
Every Container
Every Container
Every Container
Continuous
Every Piece
Every Piece
PM Completion Report
Continuous
Every Piece
Every Piece
Every Change Over
Cycle
Per Control Plan
PM Completion Report
Continuous
Start up or Change Over
Every Piece
- Glue Dispensing
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Every Piece
PM Completion Report
1/shift or Change Over
Start up or Change Over
Start up or Change Over
Per Product Spec.
Per Product Spec.
Per Product Spec.
Per Product Spec.
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Integrated Equipment
1.1 Bubble/Foam
1.1.1 Flux coverage area Sample Board
1.1.2 Exclusion zones Sample Board
1.1.3 Uniformity Sample Board
1.1.4 Via hole penetration Actual Board
1.1.5 Density of Flux/Viscosity
1.1.6 Set-up Sheet
1.1.7 1.18 Bubbler/Air Stone PM PM schedule
PROCESS TABLE F - Flux Application for Wave Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Flux density meter/Zahn Cup
Air KnifeLocation:Gap:Air Pressure:
1.2 Spray
1.2.1 Flux coverage area
1.2.2 Exclusion zones
1.2.3 Uniformity
1.2.4 Via hole penetration Actual Bare Board
1.2.5 1.18 PM schedule
1.2.6 Automatic
2.0 Stand Alone Equipment
2.1 Bubble/Foam
2.1.1 Flux coverage area Sample Board
2.1.2 Exclusion zones Sample Board
2.1.3 Uniformity Sample Board
2.1.4 Via hole penetration Actual Board
2.1.5 Density of Flux/Viscosity
Sample Board or Glass Plate
Sample Board or Glass Plate
Sample Board or Glass Plate
Preventive Maintenance CleaningChemical(s) Used:Method Used:
Prevention of air introduction into flux lines during supply change/addiition of flux
1.42.112.12
Flux density meter/Zahn Cup
2.1.6 Set-up Sheet
2.1.7 1.18 Bubbler/Air Stone PM PM schedule
2.2 Spray Correct Profile
2.2.1 Flux coverage area Sample Board
2.2.2 Exclusion zones Sample Board
2.2.3 Uniformity Sample Board
2.2.4 Via hole penetration Actual Board
2.3 2.4 Written policy
2.4 1.18 PM schedule
3.0 Manual Flux Application
3.1 Brush
3.1.1 Flux coverage area Sample Board
3.1.2 Exclusion zones Sample Board
3.1.3 Uniformity Sample Board
Air KnifeLocation:Gap:Air Pressure:
Rejected / inspected part returned to production line and inserted at the removal point.
Preventive Maintenance CleaningChemical(s) Used:Method Used:
1.42.112.12
3.1.4 Via hole penetration Actual Board
3.1.5 Brush Replacement Frequency Control Plan
3.2 Dip
3.2.1 Flux coverage area Sample Part
3.2.2 Exclusion zones Sample Part
3.2.3 Uniformity Sample Part
3.2.4 Via hole penetration Sample Part
3.2.5 Flux tank volume level control Automatic / Manual
3.3 Sponge
3.3.1 Flux coverage area Sample Board
3.3.2 Exclusion zones Sample Board
3.3.3 Uniformity Sample Board
3.3.4 Via hole penetration Actual Board
3.3.5 Sponge Replacement Frequency Control Plan
4.0 Loading (Integrated/Stand alone)
4.1 Correct Orientation
4.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
4.3 Correct Spacing
4.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training
4.5 3.9 ESD Control Per ANSI S20.20
4.6 1.15, 1.16 Proper Handling Operator Training
4.7 1.18 Equipment Cleanliness PM schedule
5.0 Unloading (Stand alone)
5.1 1.6 Proper location on conveyor Per spec/set-up
5.2 1.6 Conveyor width set properly Per spec/set-up
5.3 1.6 Conveyors covered Per spec/set-up
6.0 Component Compatibility
6.1 1.6 Flux Type correct for solder in use Component Spec
1.42.112.12
Automatic/operator training
Automatic/operator training
1.42.112.12
1.42.112.12
6.2 Flux Type matches Bill of Material (BOM) BOM
6.3 Proper flux storage condition/environment
6.4 Proper flux for specified solder Control Plan
7.0 Abnormal Condition Reaction
7.1 2.8 Power failure reaction plan Control plan
7.2 2.8 Emergency-stop reaction plan Control plan
7.3 2.8 Part jam reaction plan Control plan
7.4 2.8 Drop part reaction plan Control plan
7.5 2.8 In-Process Delay Reaction Plan Control plan
7.6 1.11 Repair/rework procedures
8.0 Manual Flux Application Handling
8.1 3.9 ESD Control Per ANSI S20.20
8.2 1.15, 1.16 Proper Handling Operator Training
© 2010 Automortive Industry Action Group (AIAG)
Manufacturer Specification
1.42.112.12
Based on IPC-7711, 7721
1.42.112.12
Monitoring Auditor Notes
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
PM Completion Report
Flux Application for Wave Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
Cover PageCover Page Index PageIndex Page
Once per shift/change over
Once per shift/change over
Once per shift/change over
PM Completion Report
Continous
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
For process initial set-up or process troubleshooting only
Once per shift/change over
PM Completion Report
Continuous
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Control Plan
PM Completion Report
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Per Control Plan
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Continuous / Check sheet
Once per shift/change over
Once per shift/change over
Once per shift/change over
Once per shift/change over
Per Control Plan
100%
100%
100%
100%
Continous
100%
PM Completion Report
Daily Check Sheet
Daily Check Sheet
Daily Check Sheet
Design Review
Daily Check Sheet
Supervisior review
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Per changeover/replenishment
ITEM # Category/Process Steps Control
1.0 Pre-Heat Equipment
1.1 3.4 Temperature controller Automatic
1.1.1 3.4 Lead Solder Correct Profile
1.1.2 3.4 Lead Free Solder Correct Profile
1.2 1.18 Zone Heating element Proper PM
1.3 Atmosphere control Automatic
1.3.1 Ventilation Automatic
1.3.2 Nitrogen supply system (if used) Automatic
1.3.3 Oxygen monitoring system (if used) Automatic
1.4 Conveyer
1.4.1 Conveyer width control Per set-up
1.4.2 Conveyer speed control Automatic
1.4.3 Conveyer Finger Cleaner Per control plan
1.5 Temperature Profile Verification
1.5.1 3.5 M.O.L.E. / Surveyor Per control plan
1.5.2 3.5 Thermal couple board placement Based on board layout
1.6 3.9 ESD Control Per ANSI S20.20
2.0 Loading
2.1 3.9 ESD Control Per ANSI S20.20
2.2 Correct Orientation
2.3 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
2.4 Correct Spacing between Boards
2.5 1.15, 1.16 Proper board placement in pallet (if used) Operator Training
2.6 Conveyer infeed cover (if required) In place
PROCESS TABLE G - Pre-Heat for Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
1.42.112.12
Automatic/operator training
Automatic/operator training
3.0 Transferring
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Conveyer cover (if required) In place
4.0 Component Compatibility
4.1 1.6 Components compatible with temperature profile Component Spec
5.0 Abnormal Condition Reaction
5.1 2.8 Power failure reaction plan Control plan
5.2 2.8 Emergency-stop reaction plan Control plan
5.3 2.8 Part jam reaction plan Control plan
5.4 2.8 Drop part reaction plan Control plan
5.5 2.8 In Process Delay Reaction Plan Control plan
5.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
1.42.112.12
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Continuous
Continuous
Continuous
Per control plan
Continuous
Continuous
Per control plan
Per control plan
Continuous
Continuous
100%
100%
100%
100%
100%
- Pre-Heat for Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Continuous
Continuous
Continuous
Design Review
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Equipment
1.1 Flux Application - See Process Table F
1.2 Pre-heat Process - See Process Table G
1.3 Wave Solder Machine
1.3.1 Solder Pot Temperature controller Automatic
1.3.2 Lead Solder
1.3.3 Lead Free Solder
1.3.4 1.18 Pot Heating element Proper PM
1.3.5 Atmosphere control Automatic
1.3.5.1 Ventilation Automatic
1.3.5.2 Nitrogen supply system (if used) Automatic
1.3.5.3 Oxygen monitoring system (if used) Automatic
1.3.6 Conveyer width control Per set-up
1.3.7 Conveyer speed control
1.3.8 Conveyer in-feed cover In place
1.3.9 Conveyer Finger Cleaner Per control plan
1.4 Temperature Profile Verification
1.4.1 M.O.L.E. / Surveyor Per control plan
1.4.2 Thermal couple board placement Based on board layout
1.5 Wave Height Control
1.5.1 Solder pump RPM Per control plan
1.5.2 Wave Vibrational Control (if used) Per control plan
1.5.3 Product sensor / timer
1.5.4 Solder pot level control Automatic
1.6 3.9 ESD Control Per ANSI S20.20
PROCESS TABLE H - Wave Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Correct Temperature Profile
Correct Temperature Profile
Automatic per Control Plan
Solder Pump Wave Control (Pump off if no product present)
1.7 Lead/Lead free changeovers
1.8 1.6 Equipment lead-free compatible
1.9 Dross Removal Frequency Per control plan
2.0 Loading
2.1 3.9 ESD Control Per ANSI S20.20
2.2 Correct Orientation
2.3 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
2.4 Correct Spacing between Boards
2.5 1.15, 1.16 Proper board placement in pallet (if used) Operator Training
2.6 Conveyer cover (if required) In place
3.0 Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Cooling/Ion Blowers
3.3.1 Filters presence Per control plan
3.3.2 1.6 Proper location on conveyor Per spec/set-up
3.3.3 Blower Operation indicator Per control plan
3.4 Magazines / Unloading racks
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Correct loading sequence (top down) Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.5 Pallet Cleaning Per control plan
4.0 Component Compatibility
4.1 1.6 Components compatible with solder temperature Component Spec
4.2 1.6 Components surface finish compatible with solder Component Spec
4.3 1.6 Solder Pot Elemental Analysis Product specification
4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing
5.0 Board Twist Control
Proper equipment cleaning
Per equipment specification
1.42.112.12
Automatic/operator training
Automatic/operator training
1.42.112.12
1.42.112.12
1.42.112.12
5.1 Maximum diagonal twist meets standard
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Per IPC-TM-650, Section 2.4.22, or per customer requirement
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Continuous
Continuous
Continuous
Per control plan
Continuous
Continuous
Continuous
Per control plan
Per control plan
Continuous
Continuous
Continuous
Continuous
Continuous
- Wave Soldering Process
The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Design Review
Check sheet
Continuous
100%
100%
100%
100%
100%
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
100%
Per control plan/changeover
Per Preventative Maintenance
Pb-free; Quarterly Lab Results, Pb; annual lab results
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Changeover/profile modification
ITEM # Category/Process Steps Control
1.0 Equipment
1.1 Flux Application See Process Table F
1.2 Pre-heat Process See Process Table G
1.3 Selective Soldering Machine
1.3.1 Solder Pot Temperature controller Automatic
1.3.2 Tin-Lead Solder Correct Temperature
1.3.3 Lead Free Solder Correct Temperature
1.3.4 1.18 Pot Heating element Proper PM
1.3.5 Atmosphere control
1.3.5.1 Ventilation Automatic
1.3.5.2 Nitrogen supply system (if used) Automatic
1.3.5.3 Oxygen monitoring system (if used) Automatic
1.3.6 Conveyer width control Per set-up
1.3.7 Conveyer index speed control
Conveyer Dwell Time
1.3.8 Conveyer infeed cover In place
1.3.9 Conveyer Finger Cleaner Per control plan
1.6 Conveyer Vertical Index Distance (if movable) Per machine spec
1.4 Temperature Profile Verification
1.4.1 M.O.L.E. / Surveyor Per control plan
1.4.2 Thermal couple board placement Based on board layout
1.5 Fountain Height Control
1.5.1 1.6 Nozzle Vertical Index Distance (if movable) Per machine spec
1.5.2 Solder pump RPM Per control plan
1.5.3 1.18 Nozzle cleanliness Proper PM
1.5.4 Solder pot level control Automatic
1.6 3.9 ESD Control Per ANSI S20.20
PROCESS TABLE I - Fountain Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
Automatic per Control Plan
1.7 Lead/Lead free changeovers
1.8 1.6 Equipment lead-free compatible
1.9 Dross Removal Frequency from Solder Pot Per control plan
1.10 Dross Removal Frequency from Nozzle area Per control plan
2.0 Transferring
2.1 3.9 ESD Control Per ANSI S20.20
2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
2.3 1.15, 1.16 Correct Spacing between Boards
2.4 1.15, 1.16 Proper board placement in pallet (if used) Operator Training
2.5 Conveyer cover (if required) In place
3.0 Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Cooling/Ion Blowers
3.3.1 Filters presence Per control plan
3.3.2 1.6 Proper location on conveyor Per spec/set-up
3.3.3 Blower Operation indicator Per control plan
3.4 Magazines / Unloading racks
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Correct loading sequence (top down) Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.4.5 Proper ESD control Per ANSI S20.20
3.5 Pallet Cleaning Per control plan
4.0 Component Compatibility
4.1 1.6 Component Spec
4.2 1.6 Components surface finish compatible with solder Component Spec
4.3 1.6 Solder Pot Elemental Analysis Product specification
4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing
5.0 Warpage Control
Proper equipment cleaning
Per equipment specification
1.42.112.12
Automatic/operator training
1.42.112.12
1.42.112.12
Components compatible with solder / pre heat temperature
1.42.112.12
5.1 Maximum diagonal warpage meets standard
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Per IPC-TM-650, Section 2.4.22, or per customer requirement
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Flow Meter
Continuous
Per control plan
Continuous
Continuous
Continuous
Continuous
Set-up Sheet
Per control plan
Per control plan
Set-up Sheet
Continuous
PM Completion Report
Continuous
Continuous
- Fountain Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Design Review
Check sheet
As needed
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Continuous
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
100%
Per control plan/changeover
Per Preventative Maintenance
Pb-free; Quarterly Lab Results, Pb; annual lab results
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Changeover/profile modification
ITEM # Category/Process Steps Control
1.0 Dip Solder Equipment
1.1 Flux Application See Process Table F
1.2 Pre-heat Process See Process Table G
1.3 Dip Soldering Machine
1.3.1 Solder Pot Temperature controller Automatic
1.3.2 Tin-Lead Solder Correct Temperature
1.3.3 Lead Free Solder Correct Temperature
1.3.4 Pot Heating element Proper PM
1.3.5 Atmosphere control
1.3.5.1 Ventilation Automatic
1.3.5.2 Nitrogen supply system (if used) Automatic
1.3.5.3 Oxygen monitoring system (if used) Automatic
1.3.6 Conveyer width control Per set-up
1.3.7 Conveyer index speed control
1.3.8 Conveyer Dwell Time
1.3.9 Conveyer Finger Cleaner Per control plan
1.3.10 Conveyer Vertical Index Distance (if movable) Per machine spec
1.4 Temperature Profile Verification
1.4.1 M.O.L.E. / Surveyor Per control plan
1.4.2 Thermal couple board placement Based on board layout
1.5.1 Solder circulation pump (if used) Per control plan
1.5.2 Solder pot level control Automatic
1.6 3.9 ESD Control Per ANSI S20.20
1.7 Lead/Lead free changeovers
1.8 1.6 Equipment lead-free compatible
PROCESS TABLE J - Dip Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
Automatic per Control Plan
Proper equipment cleaning
Per equipment specification
1.9 Per control plan
2.0 Transferring
2.1 3.9 ESD Control Per ANSI S20.20
2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
2.3 1.15, 1.16 Correct Spacing between Boards
2.4 1.15, 1.16 Proper board placement in pallet (if used) Operator Training
2.5 Conveyer cover (if required) In place
3.0 Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Cooling/Ion Blowers
3.3.1 Filters presence Per control plan
3.3.2 1.6 Proper location on conveyor Per spec/set-up
3.3.3 Blower Operation indicator Per control plan
3.4 Magazines / Unloading racks
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Correct loading sequence (top down) Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.5 Pallet Cleaning Per control plan
4.0 Component Compatibility
4.1 1.6 Component Spec
4.2 1.6 Components surface finish compatible with solder Component Spec
4.3 1.6 Solder Pot Elemental Analysis Product specification
4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing
5.0 Warpage Control
5.1 Maximum diagonal warpage meets standard
6.0 Abnormal Condition Reaction
Dross Removal Frequency from Solder Pot (if required)
1.42.112.12
Automatic/operator training
1.42.112.12
1.42.112.12
Components compatible with solder / pre heat temperature
1.42.112.12
Per IPC-TM-650, Section 2.4.22, or per customer requirement
1.42.112.12
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Flow Meter
Continuous
Per control plan
Continuous
Continuous
Continuous
Set-up Sheet
Per control plan
Per control plan
Continuous
Continuous
Continuous
Design Review
- Dip Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Per control plan/changeover
Cover PageCover Page Index PageIndex Page
Check sheet
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
100%
Per Preventative Maintenance
Pb-free; Quarterly Lab Results, Pb; annual lab results
Changeover/profile modification
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Equipment
1.1 Flux Application See Process Table F
1.2 Pre-heat Process See Process Table G
1.3 Temperature controller Automatic
1.3.1 Tin-Lead Solder Correct Profile
1.3.2 Lead Free Solder Correct Profile
1.4 Heating element Proper PM
1.5 Atmosphere control
1.5.1 Ventilation Automatic
1.5.2 Nitrogen supply system (if used) Automatic
1.5.3 Oxygen monitoring system (if used) Automatic
1.5.4 Solder pot level control Automatic
1.6 Conveyers
1.6.1 Width control Per set-up
1.6.2 Speed control
1.6.3 Infeed cover In place
1.6.4 Finger Cleaner Per control plan
1.7 M.O.L.E. / Surveyor
1.7.1 Thermal couple board placement Based on board layout
1.7.2 Frequency of sampling Per control plan
1.8 Solder supply control
1.8.1 Solder pump RPM (if used) Per control plan
1.8.2 Wave Vibrational Control (if used) Per control plan
1.9 3.9 ESD Control Per ANSI S20.20
1.10 Lead/Lead free changeovers
1.11 1.6 Equipment lead-free compatible
PROCESS TABLE K - Selective Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
Proper equipment cleaning
Per equipment specification
1.12 Dross Removal Frequency Per control plan
2.0 Loading
2.1 Correct Orientation
2.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
2.3 1.15, 1.16 Correct Spacing
2.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training
3.0 Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Cooling/Ion Blowers
3.3.1 Filters presence Per control plan
3.3.2 1.6 Proper location on conveyor Per spec/set-up
3.3.3 Blower Operation indicator Per control plan
3.4 Magazines / Unloading racks
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Correct loading sequence (top down) Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.5 Pallet Cleaning Per control plan
4.0 Component Compatibility
4.1 1.6 Component Spec
4.2 1.6 Components compatible with solder Component Spec
4.3 1.6 Solder Pot Elemental Analysis Product specification
4.4 Prevention of Pb/Pb-free solder bar mix Proper error-proofing
5.0 Warpage Control
5.1 Maximum diagonal warpage meets standard
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
1.42.112.12
Automatic/operator training
Automatic/operator training
1.42.112.12
1.42.112.12
Components compatible with solder / pre heat temperature
1.42.112.12
Per IPC-TM-650, Section 2.4.22, or per customer requirement
1.42.112.12
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Continuous
Continuous
PM Completion Report
Continuous
Continuous
Continuous
Continuous
Per control plan
Continuous
Continuous
Continuous
Per control plan
Per control plan
Continuous
Continuous
Continuous
Design Review
- Selective Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Per control plan/changeover
Cover PageCover Page Index PageIndex Page
Check sheet
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
100%
Continuous
Per Preventative Maintenance
Pb-free; Quarterly Lab Results, Pb; annual lab results
Changeover/profile modification
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Equipment
1.1 Flux Application (if used) See Process Table F
1.2 Pre-heat Process (if used) See Process Table G
1.3 Conveyer
1.3.1 Width control Per set-up
1.3.2 Speed/index control
1.3.3 Infeed cover In place
1.4 Soldering Iron
1.4.1 Temperature controller Correct Temperature
1.4.2 1.18 Heating element Proper PM
1.4.3 1.6 Iron tip temperature calibration Per specification
1.4.4 1.6 Correct Tip (shape/size/material) Per specification
1.4.5 Iron tip cleaner Per control plan
1.4.6 1.18 Iron tip maintenance Proper PM
1.5 Solder
1.5.1 1.6 Correct Solder (type/size/core) Per specification
1.5.2 Solder Lot Control Bar Code or Manual
1.6 Atmosphere control
1.6.1 Ventilation Automatic
PROCESS TABLE L - Automated Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
1.6.2 Nitrogen supply system (if used) Automatic
1.6.3 Oxygen monitoring system (if used) Automatic
1.7 3.9 ESD Control Per ANSI S20.20
1.8 Pb/Pb free changeovers
1.9 Solder ball control
2.0 Automated Solder Process Control
2.1 1.6 Tip contact position Per product spec
2.2 1.6 Tip contact dwell time Per product spec
2.3 1.6 Solder contact position Per product spec
2.4 1.6 Solder feed rate Per product spec
2.5 1.6 Angle of contact Per product spec
3.0 Loading
3.1 1.15, 1.16 Correct Orientation
3.2 1.15, 1.16 Stiffeners (if used) correct placement Operator Training
3.3 1.15, 1.16 Correct Spacing
3.4 1.15, 1.16 Proper placement in pallet (if used) Operator Training
4.0 Unloading
4.1 3.9 ESD Control Per ANSI S20.20
4.2 1.15, 1.16 Proper Handling Operator Training
4.3 Cooling/Ion Blowers
4..3.1 Filters presence Per control plan
4.3.2 1.6 Proper location on conveyor Per spec/set-up
4.3.3 Blower Operation indicator Per control plan
4.4 Magazines / Unloading racks Per product spec
Proper equipment cleaning
Solder preparation per customer agreement (e.g., V-groove cutter)
1.42.112.12
1.42.112.12
Automatic/operator training
Automatic/operator training
1.42.112.12
4.4.1 Correct Type for product (Pb/Pb free) Per control plan
4.4.2 Correct width and height for product Per control plan
4.4.3 Correct loading sequence (top down) Per control plan
4.4.4 Covered for transportation and storage Per control plan
4.5 Pallet Cleaning Per control plan
5.0 Component Compatibility
5.1 1.6 Components compatible with iron temperature Component Spec
5.2 1.6 Components compatible with solder Component Spec
6.0 Warpage Control
6.1
7.0 Abnormal Condition Reaction
7.1 2.8 Power failure reaction plan Control plan
7.2 2.8 Emergency-stop reaction plan Control plan
7.3 2.8 Part jam reaction plan Control plan
7.4 2.8 Drop part reaction plan Control plan
7.5 2.8 In Process Delay Reaction Plan Control plan
7.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
1.42.112.12
Maximum diagonal warpage meets standard (warpage of the PCB cannot be affected by this process).
Per IPC-TM-650, Section 2.4.22
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Per control plan
Continuous
Continuous
Continuous
PM Completion Report
Per control plan
Per control plan
Continuous
PM Completion Report
Per control plan
Per control plan
Continuous
- Automated Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Continuous
Continuous
Continuous
100%
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
Per Changeover
Per control plan/changeover
Per Preventative Maintenance
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Changeover/profile modification
ITEM # Category/Process Steps Control
1.0 Equipment
1.1 Flux Application (if used) See Process Table F
1.2 Pre-heat Process (if used) See Process Table G
1.3 Soldering Iron
1.3.1 Temperature controller Correct Temperature
1.3.2 Heating element Proper PM
1.3.3 1.6 Iron tip temperature calibration Per specification
1.3.4 1.6 Correct Tip (shape/size/material) Per specification
1.3.5 Iron tip cleaner Per control plan
1.3.6 Iron tip maintenance Proper PM
1.3.7 Iron tip cleaner Per control plan
1.4 Solder
1.4.1 1.6 Correct Solder (type/size/core) Per specification
1.4.2 Solder Lot Control Bar Code or Manual
1.5 Atmosphere control
1.5.1 Ventilation Automatic
1.5.2 Nitrogen Soldering Protection (if used)
1.6 3.9 ESD Control Per ANSI S20.20
1.7 Pb/Pb free changeovers
PROCESS TABLE M - Manual Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Proper equipment cleaning
1.8 Solder ball control
2.0 Manual Solder Process Control
2.1
3.0 Loading/Unloading
3.1 3.9 ESD Control Per ANSI S20.20
3.2 1.15, 1.16 Proper Handling Operator Training
3.3 Ionizers
3.3.1 Filters presence Per control plan
3.3.2 1.6 Proper location on conveyor Per spec/set-up
3.3.3 Blower Operation indicator Per control plan
3.3.4 Proper maintenance Proper PM
3.4 1.6 Magazines / Unloading racks Per product spec
3.4.1 Correct Type for product (Pb/Pb free) Per control plan
3.4.2 Correct width and height for product Per control plan
3.4.3 Correct loading sequence (top down) Per control plan
3.4.4 Covered for transportation and storage Per control plan
3.5 Pallet Cleaning Per control plan
4.0 Component Compatibility
4.1 1.6 Components compatible with iron temperature Component Spec
4.2 1.6 Components compatible with solder Component Spec
5.0 Warpage Control
5.1 Maximum diagonal warpage meets standard
6.0 Abnormal Condition Reaction
Solder preparation per customer agreement (e.g., V-groove cutter)
1.42.112.12
Soldering techniques, such as; dwell times, methods of iron application to joint.
Retraining provided when quality issues indicate
1.42.112.12
1.42.112.12
1.42.112.12
Per IPC-TM-650, Section 2.4.22
1.42.112.12
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
PM Completion Report
Per control plan
Per control plan
Continuous
PM Completion Report
Continuous
Per control plan
Per control plan
Continuous
Continuous
- Manual Iron Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Per control plan/changeover
Cover PageCover Page Index PageIndex Page
100%
Post solder inspection
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
PM Completion Report
Per Changeover
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
Per Preventative Maintenance
Changeover/profile modification
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Laser - Soft Beam Solder Equipment
1.1 Automated Flux Application See Process Table F
1.2 Manual Flux Application
1.2.1 1.15, 1.16 Correct Flux Type Operator Training
1.2.2 1.15, 1.16 Correct Applicator Operator Training
1.2.3 1.15, 1.16 Correct Amount and Location Operator Training
1.2.4 Time
1.3 Conveyer
1.3.1 Conveyer width control Per set-up
1.3.2 Conveyer speed control
1.3.3 Conveyer infeed cover In place
1.4 Pre-heat Process (if used) See Process Table G
2.0 Laser Equipment Controls
2.1 Correct Laser Wave Length Per Control Plan
2.2 Correct Laser Power Per Control Plan
2.3 Correct Laser Alignment Per Control Plan
2.4 Correct Laser Exposure Time Per Control Plan
2.5 Correct Laser Focus (Spot Size) Per Control Plan
PROCESS TABLE N - Laser - Soft Beam Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
1.42.112.12
3.0 Soft Beam Equipment Controls
3.1 Correct Xenon Lamp Per Control Plan
3.2 Correct Power Setting Per Control Plan
3.3 Correct Alignment Per Control Plan
3.4 Correct Exposure Time Per Control Plan
3.5 Correct Focus (Spot Size) Per Control Plan
3.6 3.9 ESD Control Per ANSI S20.20
3.7 Lead/Lead free changeovers
4.0 Loading/Unloading
4.1 3.9 ESD Control Per ANSI S20.20
4.2 1.15, 1.16 Proper Handling Operator Training
4.3 Cooling/Ionizer Blower
4.3.1 Filters presence Per control plan
4.3.2 1.6 Proper location on conveyor Per spec/set-up
4.3.3 Blower Operation indicator Per control plan
4.3.4 Proper maintenance Proper PM
4.4 1.6 Magazines / Unloading racks Per product spec
4.4.1 Correct Type for product (Pb/Pb free) Per control plan
4.4.2 Correct width and height for product Per control plan
4.4.3 Correct loading sequence (top down) Per control plan
4.4.4 Covered for transportation and storage Per control plan
4.5 Pallet Cleaning Per control plan
5.0 Component Compatibility
5.1 1.6 Components compatible with temperature profile Component Spec
5.2 1.6 Components compatible with solder Component Spec
1.42.112.12
Proper equipment cleaning
1.42.112.12
1.42.112.12
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Emergency-stop reaction plan Control plan
6.3 2.8 Part jam reaction plan Control plan
6.4 2.8 Drop part reaction plan Control plan
6.5 2.8 In Process Delay Reaction Plan Control plan
6.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Per Training Plan
Per Training Plan
Per Training Plan
Per control plan
Continuous
Continuous
Per Specification
Per Set-Up Sheet
Per Set-Up Sheet
Per Set-Up Sheet
Per Set-Up Sheet
- Laser - Soft Beam Soldering ProcessThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Per Specification
Per Set-Up Sheet
Per Set-Up Sheet
Per Set-Up Sheet
Per Set-Up Sheet
Continuous
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
PM Completion Report
Per Changeover
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Design Review
Per control plan/changeover
Per Preventative Maintenance
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Solder Paste Control (Pre-mixed only)
1.1 1.6 Correct solder paste Specification
1.2 1.6 Correct storage conditions Specification
1.3 1.6 Correct stabilization Specification
1.4 1.6 Ambient temperature exposure Specification
2.0 Solder Paste Application
2.1 1.6 Dispensed volume Specification
2.2 1.6 Correct dispense location Specification
2.3 Nozzle condition Control Plan
3.0 Part Placement
3.1 1.6 Stationary part accuracy
3.2 1.6 Placement verification
3.3 1.6 Movable part accuracy
3.4 1.6 Movable part verification
3.5 1.6 Gap between parts to be soldered
4.0 Equipment Control
4.1 1.6 Power Supply Frequency Per Specification
PROCESS TABLE O - InductionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
1.42.112.12
1.42.112.12
Per Set-Up Specification
Per Set-Up Specification
Per Set-Up Specification
Per Set-Up Specification
Per Set-Up Specification
1.42.112.12
4.2 1.6 Inductive Head Position (Hot Spot position control) Per Specification
4.3 1.6 Inductive Head to Part Gap Per Specification
4.4 1.6 Power Profile Per Specification
4.5 1.6 Power Duration per Soldering Cycle Per Specification
4.6 1.6 Inductive Head Cooling Air Flow Rate Per Specification
4.7 1.6 Magnetic Flux Monitoring Per Specification
5.0 Final Inspection
5.1 1.6 Quality Inspection Audit Per Specification
5.2 Non-conforming part disposition Reaction plan
6.0 Loading/Unloading
6.1 3.9 ESD Control Per ANSI S20.20
6.2 1.15, 1.16 Proper Handling Operator Training
6.3 Cooling/Ionizer Blower
6.3.1 Filters presence Per control plan
6.3.2 1.6 Proper location on conveyor Per spec/set-up
6.3.3 Blower Operation indicator Per control plan
6.3.4 1.18 Proper maintenance Proper PM
6.4 1.6 Magazines / Unloading racks Per product spec
6.4.1 Correct Type for product (Pb/Pb free) Per control plan
6.4.2 Correct width and height for product Per control plan
6.4.3 Correct loading sequence (top down) Per control plan
6.4.4 Covered for transportation and storage Per control plan
6.5 Pallet Cleaning Per control plan
7.0 Component Compatibility
7.1 1.6 Components compatible with temperature profile Component Spec
1.42.112.12
1.42.112.12
1.42.112.12
7.2 1.6 Components compatible with solder Component Spec
8.0 Abnormal Condition Reaction
8.1 2.8 Power failure reaction plan Control plan
8.2 2.8 Emergency-stop reaction plan Control plan
8.3 2.8 Part jam reaction plan Control plan
8.4 2.8 Drop part reaction plan Control plan
8.5 2.8 In Process Delay Reaction Plan Control plan
8.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Start-up and changeover
Continuous
Start-up and changeover
Continuous
Start-up and changeover
Continuous
Start-up and changeover
Continuous
Once per Day
Continuous
Once per Day
Once per Day
Start-up and changeover
- InductionThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Cover PageCover Page Index PageIndex Page
Start-up and changeover
Start-up and changeover
Start-up and changeover
Start-up and changeover
Start-up and changeover
Start-up and changeover
Per Control Plan
Per Control Plan
Continuous
Continuous
Daily Check Sheet
Daily Check Sheet
PM Completion Report
Per Changeover
Continuous
Continuous
Continuous
Continuous
Per Control Plan
Design Review
Per Preventative Maintenance
Design Review
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Conformal Coating
1.6 Type Used: Per Specification
1.6 Curing Method: Per Specification
2.0 Preparation
2.1 Pre-Mixed:
2.1.1 1.6 Correct Storage Conditions Per Specifications
2.1.2 1.6 Stabilized to operating temperature Per Specifications
2.1.3 Correct Material Bar Code or Manual
2.1.4 Expiration Date/Lot Control Bar Code or Manual
2.1.5 Expired Material Handling Per Control Plan
2.2 On-site Mixed:
2.2.1 1.6 Correct Storage Conditions for Components Per Specifications
2.2.2 1.6 Correct mixing temperature Per Specifications
2.2.3 Correct Material Bar Code or Manual
2.2.4 Ingredient Expiration Date/Lot Control Bar Code or Manual
2.2.5 Expired ingredients handling Per Control Plan
2.2.6 Mixing tools calibrated Per Control Plan
2.2.7 Cleanliness of mixing containers and work area No foreign materials
2.2.8 1.6 Mixing time Per Specifications
2.2.9 1.6 Viscosity confirmation Per Specifications
2.2.10 1.6 Prepared conformal coating expiration date Per Specifications
3.0 Coating Application
3.1 Spray - Automatic or Manual
PROCESS TABLE P - Conformal CoatingThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
1.42.112.12
1.42.112.12
3.1.1 1.6 Correct Coverage Area Per Specification
3.1.2 1.6 No Coating / Overspray In Exclusion Zone Per Specification
3.1.3 1.6 Correct Thickness / Uniformity Per Specification
3.1.4 Solution Flow Rate (if 3.1.3 not applicable) Per Control Plan
3.1.5 Solution Pressure Rate Per Control Plan
3.1.6 Nozzle Movement Speed Per Control Plan
3.1.7 1.18 Nozzle Maintenance
3.1.8 1.6 Masking (Manual Spray Only) Per Specification
1.6 Board and Solution Temperature
3.2 Dip - Automatic or Manual
3.2.1 1.6 Correct Coverage Area Per Specification
3.2.2 1.6 Correct Thickness / Uniformity
3.2.3 No Foreign Material in Pot Proper Filtering
3.2.4 1.6 Uniform viscosity maintenance
3.2.5 Insert and Withdraw Rate / Soak Time Per Control Plan
3.2.6 1.6 Correct board orientation Per Specification
3.2.7 1.6 Board and Tank Temperature
3.2.8 1.6 Drip Time
3.3 Brush
3.3.1 1.6 Correct Brush Type Per Specification
3.3.2 1.6 Correct Coverage Area Per Specification
3.3.3 1.6 No Coating / Oversplash In Exclusion Zone Per Specification
3.3.4 1.6 Correct Thickness / Uniformity Per Specification
3.3.5 1.6 Masking (If Required) Per Specification
3.3.6 1.6 Uniform viscosity maintenance
3.3.7 1.6 No Foreign Material in Pot Per Specification
3.3.8 1.6 Board and Tank Temperature
3.3.9 Proper ESD Control Per ANSI S20.20
3.4 Selective Coverage Area
3.4.1 1.6 Correct Coverage Area Per Specification
3.4.2 1.6 No Coating / Drips In Exclusion Zone Per Specification
3.4.8 1.6 Board and Solution Temperature
3.4.9 1.15, 1.16
Per Preventive Maintenance Schedule
Per Product Specification
Per Specification and Control Plan
Per Product Specification
Per Product Specification
Per Product Specification
Per Product Specification
Per Product Specification
Per Product Specification
Proper Coverage for Manual Applications with controls as above
Proper Operator Training
4.0 Curing
4.1 Ultra Violet (UV) Cure
4.1.1 1.6 Proper UV Source Per Specification
4.1.2 1.6 Proper Exposure Time Per Specification
4.1.3 1.6 Debris Control Per Specification
4.1.4 1.6 Correct Orientation Per Specification
4.1.5 Proper UV Source Maintenance
4.1.6 1.6 Humidity Control
4.2 Humidity Cure
4.2.1 1.6 Correct Temperature / Humidity Range Per Specification
4.2.2 1.6 Proper Exposure Time Per Specification
4.2.3 1.6 Debris Control Per Specification
4.2.4 1.6 Correct Orientation Per Specification
4.3 Heat Cure
4.3.1 1.6 Correct Temperature Level Per Specification
4.3.2 1.6 Proper Exposure Time Per Specification
4.3.3 1.6 Debris Control Per Specification
4.3.4 1.6 Correct Orientation Per Specification
4.3.5 1.6 Proper Humidity Level Per Specification
4.4 Ambient Cure
4.4.1 1.6 Correct Temperature / Humidity Range Per Specification
4.4.2 1.6 Proper Cure Time Per Specification
4.4.3 1.6 Debris Control Per Specification
4.4.4 1.6 Correct Orientation Per Specification
5.0 Inspection
5.1 1.15, 1.16 Proper Coverage Area Operator Training
5.2 No Bubbles, Voids, or Inconsistencies None Allowed
5.3 Thickness Check
5.4 1.15, 1.16 Curing Completion Operator Training
5.5 3.9 Proper ESD Control Per ANSI S20.20
6.0 General
6.1 Fixture cleaning frequency Per Control Plan
6.2 Appropriate operator protective equipement
1.42.112.12
Per Preventive Maintenance Schedule
Per Coating Specifications
1.42.112.12
Per Product Specification
1.42.112.12
Per work area requirement
7.0 Abnormal Condition Reaction
7.1 2.8 Power failure reaction plan Control plan
7.2 2.8 Emergency-stop reaction plan Control plan
7.3 2.8 Part jam reaction plan Control plan
7.4 2.8 Drop part reaction plan Control plan
7.5 2.8 In Process Delay Reaction Plan Control plan
7.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Check sheet
Every Container
Every Container
Per Control Plan
Per Control Plan
Check sheet
Every Container
Every Container
Per Control Plan
Per Calibration Cycle
Check sheet
Check sheet
Check sheet
- Conformal CoatingThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Error-Proofing Check Sheet
Error-Proofing Check Sheet
Per Control Plan/Work Instructions
Cover PageCover Page Index PageIndex Page
Set-up Sheet
Set-up Sheet
Set-up Sheet
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Continuous
Set-up Sheet
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Continuous
Continuous
Set-up Sheet
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Set-up Sheet
Set-up Sheet
Continuous
Continuous
Set-up Sheet
Set-up Sheet
Continuous
Visual Control
Maintenance Check Sheet
PM Schedule per customer requirement
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Continuous
Set-up Sheet
Set-up Sheet
Set-up Sheet
Continuous
Continuous
Continuous
Per Sampling Plan
Continuous
Continuous
Per Schedule
100%
Maintenance Check Sheet
Plant Level:Equipment Level:
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Router
1.1 1.6 Correct router pattern Specification
1.2 1.6 Correct bit Specification
1.3 1.6 Correct bit alignment Specification
1.4 1.6 Correct RPM Specification
1.5 Correct debris removal Proper vacuum level
1.6 No abnormal board flex
1.7 3.9 ESD control Per ANSI S20.20
1.8 1.15, 1.16 Proper seating of PCB Operator training
1.9 1.6 Proper support for separated panels Specification
1.10 1.15, 1.16 Proper handling during loading and unloading Operator training
1.11 1.18 Established bit preventive maintenance
1.12 Reaction plan to broken bit Per Control Plan
2.0 Die/Punch
2.1 Correct die/punch Set-up Sheet
2.2 1.6 Correct PCB to die/punch alignment Specification
2.3 1.6 Correct force Specification
2.4 Correct debris removal Per control plan
2.5 No abnormal board flex
PROCESS TABLE Q - PCB SeparationThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Per Customer requirement
Per Preventive Maintenance Schedule
1.42.112.12
Per Customer requirement
2.6 3.9 ESD control Per ANSI S20.20
2.7 1.15, 1.16 Proper seating of PCB Operator training
2.8 1.6 Proper support for separated panels Specification
2.9 1.15, 1.16 Proper handling during loading and unloading Operator training
2.10 1.18 Established die/punch preventive maintenance
2.11 Reaction plan to broken die/punch Per Control Plan
3.0 Blade (V-cut)
3.1 Correct blade Set-up Sheet
3.2 1.6 Correct PCB to blade alignment Specification
3.3 1.6 Correct PCB to blade gap Specification
3.4 Correct debris removal Pre control plan
3.5 No abnormal board flex
3.6 3.9 ESD control Per ANSI S20.20
3.7 1.15, 1.16 Proper seating of PCB Operator training
3.8 1.6 Proper support for separated panels Specification
3.9 1.15, 1.16 Proper handling during loading and unloading Operator training
3.10 1.18 Established blade preventive maintenance
3.11 Reaction plan to damage blade Per Control Plan
4.0 Manual Separation
4.1 Correct debris removal Pre control plan
4.2 No abnormal board flex
4.3 3.9 ESD control Per ANSI S20.20
4.4
4.5 Proper handling during separation activity
4.6 Proper tools specified
Per Preventive Maintenance Schedule
1.42.112.12
Per Customer requirement
Per Preventive Maintenance Schedule
1.42.112.12
Per Customer requirement
Procedure in place to ensure separation method meets customer requirements
Per Customer requirement
Per Customer requirement
Per Customer requirement
5.0 Abnormal Condition Reaction
5.1 2.8 Power failure reaction plan Control plan
5.2 2.8 Emergency-stop reaction plan Control plan
5.3 2.8 Part jam reaction plan Control plan
5.4 2.8 Drop part reaction plan Control plan
5.5 2.8 In Process Delay Reaction Plan Control plan
5.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
1.42.112.12
Based on IPC-7711, 7721
Monitoring Auditor Notes
Continuous
Start-up or change over
Start-up or change over
Start-up or change over
Continuous
Continuous
Continuous
Continuous
Continuous
Start-up or change over
Start-up or change over
Start-up or change over
Continuous
- PCB SeparationThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Start of production or equipment change/modification
Start-up or equipment change-over
Maintenance Check Sheet
Start of production or equipment change/modification
Cover PageCover Page Index PageIndex Page
Continuous
Continuous
Continuous
Continuous
Start-up or change over
Start-up or change over
Start-up or change over
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Start-up or equipment change-over
Maintenance Check Sheet
Start of production or equipment change/modification
Start-up or equipment change-over
Maintenance Check Sheet
Start of production or equipment change/modification
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
ITEM # Category/Process Steps Control
1.0 Automatic
1.2 Conveyer width control Per set-up
1.3 Conveyer index control
1.4 Conveyers covered Covers in place
1.5 Proper positioning for test Per set-up
1.6 Per set-up
1.7 Per set-up
1.8 Correct dwell (test/set) time Per set-up
1.9 Good/bad boundary sample confirmation
1.10 Proper test equipment calibration
1.11 Failed part data logging Per each failed part
1.12 Failed part traceability
1.13 Reaction plan to high level of false-fails Per reaction plan
1.14 Reaction plan to defective part limits Per reaction plan
1.15 1.18
1.16 3.9 ESD control Per ANSI S20.20
PROCESS TABLE R - In-circuit Testing (ICT)The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Automatic per Control Plan
Correct test set-up:SoftwareHardware
Correct pin set-up:Clearance between pinsHeightPressureType
Start-up/changeover and last off
Per calibration frequency
Per identification method
Preventative maintenance performed (confirm pogo pin inspection/replacement criteria)
Per Preventive Maintenance Schedule
1.17 No abnormal board flex
2.0 Manual
2.1 1.15, 1.16 Correct loading/unloading Operator training
2.2 Proper positioning for test Per set-up
2.3 Per set-up
2.4 Per set-up
2.5 Correct dwell (test/set) time Per set-up
2.6 Good/bad boundary sample confirmation
2.7 Proper test equipment calibration
2.8 Failed part data logging Per each failed part
2.9 Failed part traceability
2.10 Reaction plan to high level of false-fails Per reaction plan
2.11 Reaction plan to defective part limits Per reaction plan
2.12 1.18
2.13 3.9 ESD control Per ANSI S20.20
2.14 No abnormal board flex
3.0 Abnormal Condition Reaction
3.1 2.8 Power failure reaction plan Control plan
3.2 2.8 Emergency-stop reaction plan Control plan
3.3 2.8 Part jam reaction plan Control plan
3.4 2.8 Drop part reaction plan Control plan
3.5 2.8 In-Process Delay Reaction Plan Control plan
Per Customer requirement
1.42.112.12
Correct test set-up:SoftwareHardware
Correct pin set-up:Clearance between pinsHeightPressureType
Start-up/changeover and last off
Per calibration frequency
Per identification method
Preventative maintenance performed (confirm pogo pin inspection/replacement criteria)
Per Preventive Maintenance Schedule
Per Customer requirement
1.42.112.12
3.6 1.11 Repair/rework procedures
© 2010 Automortive Industry Action Group (AIAG)
Based on IPC-7711, 7721
Monitoring Auditor Notes
Per control plan
Continuous
Continuous
Per control plan
Per control plan
Per control plan
Per control plan
Per control plan
Per control plan
Continuous
Per control plan
Per control plan
Continuous
- In-circuit Testing (ICT)The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Per equipment manufacturer recommendation
Maintenance Check Sheet
Cover PageCover Page Index PageIndex Page
Per control plan
Per control plan
Per control plan
Per control plan
Per control plan
Per control plan
Per control plan
Continuous
Per control plan
Per control plan
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Start of production or equipment change/modification
Per equipment manufacturer recommendation
Maintenance Check Sheet
Start of production or equipment change/modification
Continuous
ITEM # Category/Process Steps Control
1.0 On-line Re-work
1.1 Confirmation of defective part
1.2 Written procedure
1.3 Traceability linked to part repair history Written procedure
1.4 Identify effective area of defect
1.5 Identify defective component
1.6
1.7 Written procedure
1.8 1.15, 1.16 Operator certification for diagnostic and repairs Operator training
1.9 Repair confirmed by certified supervisor/team leader
1.10 Written policy
1.11 3.9 ESD handling procedure in place Per ANSI S20.20
1.12 Solder ball control
PROCESS TABLE S - Solder Re-workThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify Soldering Organization is conforming to customer requirements.
Related SSA
Question
1.42.112.12
Defect class defined per customer agreement
Procedure to track defective part from the process through re-work
Quality confirmation systems
Quality confirmation systems
Identification method for reworkable components. (Proper IC orientation / part polarity)
Written policy or customer requirements
Removal of conformal coating, if required (not recommended)
Written policy or customer requirements
Repaired part returned to production line and inserted prior to defect identification/reject point
Solder preparation per customer agreement (e.g., V-groove cutter)
2.0 Off-line Repair Procedure
2.1 Confirmation of defective part
2.2 Written procedure
2.3 Traceability linked to part repair history Written procedure
2.4 Off-line part handling and storage procedure Written procedure
2.5 Identify effective area of defect Inspection results
2.6 Identify defective component Inspection results
2.7 Identification method for reworkable components.
2.8 Written procedure
2.9 1.15, 1.16 Operator certification for diagnostic and repairs Operator training
2.10 Repair confirmed by certified supervisor/team leader
2.11 Written policy
2.12 3.9 ESD handling procedure in place Per ANSI S20.20
3.0 Repair Equipment and Material
3.1
3.2 All tools indentified for Pb versus Pb free
3.3 Solder iron
3.3.1 Correct Iron Temperature Per specification
3.3.2 Heating element Per specification
3.3.3 Iron tip temperature calibration Per specification
3.3.4 Correct Tip (shape/size/material) Per specification
3.3.5 Correct Solder (type/size/core) Per specification
3.3.6 Solder Lot Control Bar Code or Manual
1.42.112.12
Defect class defined per customer agreement
Defective parts tracked from the process through re-work
Written policy or customer requirements
Removal of conformal coating, if required (not recommended)
Written policy or customer requirements
Repaired part returned to production line and inserted prior to defect identification/reject point
1.42.112.12
Work stations identified for Pb versus Pb-free material
Visual identification and documentation
Visual identification and documentation
3.3.7 Atmosphere control Automatic
3.3.8 Ventilation Automatic
3.3.9 3.9 ESD Control Per ANSI S20.20
3.3.10 Iron tip cleaner Per control plan
3.3.11 Iron tip maintenance
3.4
3.4.1 Removal - Localized pre-heat control
3.4.2 Removal - Pre-heat temperature set point
3.4.3 Removal - Pre-heat time control
3.4.4 Proper pad inspection post-removal Operator training
3.4.5 Insertion - Pre-heat control
3.4.6 Insertion - Reflow temperature control
3.4.7 Insertion - Reflow time control
3.4.8 Post insertion - Cooling profile
3.4.9 Heater head cleaning procedure
3.5 Component Control
3.5.1 Replacement component match bill of material
3.5.2
3.5.3 Component matches solder type used
3.5.4 Disposition of defective components
3.6 Conformal Coat removal and replacement
3.7.1 Solvent removal Procedure in place
3.7.2 Correct solvent for coating used
Per Preventive Maintenance Schedule
1.42.112.12
BGA/Flip Chip/Bumped Die/Controlled Collapse Chip Connection (C4) Repair Equipment
Automatic based on part requirements
Automatic based on part requirements
Automatic based on part requirements
Automatic based on part requirements
Automatic based on part requirements
Automatic based on part requirements
Automatic based on part requirements
Per equipment OEM specifications
1.42.112.12
BOM verification / crosscheck
Proper moisture sensitive device (MSD) environmental control/tracking
Per component requirements
BOM verification / crosscheck
Scrap / non-conforming part procedure
1.42.112.12
Procedure / checksheet
3.7.3 1.15, 1.16 Mechanical dam installed around component
3.7.4 1.15, 1.16 Filler used for solvent to prevent run out
3.7.5 1.15, 1.16 Board cleaned before re-work
3.8 Micro-abrasive removal
3.8.1 1.15, 1.16 Only nonconductive abrasive allowed
3.8.2 1.15, 1.16 Mask used to protect surrounding components
3.8.3 1.15, 1.16 Board cleaned before re-work
3.9 Mechanical removal
3.9.1 1.15, 1.16 Proper tool
3.9.2 1.15, 1.16 No damage allowed to solder resist
3.10 1.15, 1.16 De-soldering removal
3.10.1 1.15, 1.16 Proper iron temperature to vaporize coating
3.10.2 1.15, 1.16 Proper ventilation for operator protection
3.11 Reapplication
3.11.1 1.15, 1.16
3.11.2 1.15, 1.16
3.11.3 1.15, 1.16
4.0 Encapsulated / Potted Component Rework Not recommended
5.0 Proper work station cleanliness Operator training
6.0 Abnormal Condition Reaction
6.1 2.8 Power failure reaction plan Control plan
6.2 2.8 Drop part reaction plan Control plan
6.3 2.8 In Process Delay Reaction Plan Control plan
6.4 1.11 Repair/rework procedures
6.5 1.11 Maximum number of repairs allowed per board
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Procedure / Operator training
Silicone paste conformal coat only one part moisture cured solution allowed
Procedure / Operator training
Non-silicone paste adhesion promoter should be used as needed
Procedure / Operator training
All repairs require at least 3 millimeters overlap of demarcation edges of existing coatings
Procedure / Operator training
1.42.112.12
1.42.112.12
1.42.112.12
Based on IPC-7711, 7721
Per customer product specification
© 2010 Automortive Industry Action Group (AIAG)
Monitoring Auditor Notes
Automatic test
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Continuous
100%
- Solder Re-workThe contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company.
Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive
All requirements given below are subordinate to customer specific requirements.
The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the Soldering Organization is conforming to customer requirements.
Training matrix with annual management review.
Cover PageCover Page Index PageIndex Page
Automatic test
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Control Plan
Continuous
Continuous
Continuous
Quality audit
Per PM Schedule
Per control plan
Per control plan
Per control plan
Per control plan
Training matrix with annual management review.
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
PM completion reports
Continuous
Continuous
Continuous
Continuous
Supervisor confirmation
Supervisor confirmation
Maintenance Check Sheet
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Supervisor confirmation
Continuous
Continuous
Continuous
Continuous
Effective tracking system
REQUIREMENT CATEGORIES
SP Special Processes
1 0 Heat Treat Services Provided [YES / NO]
2 0 Plating Services Provided [YES / NO]
3 0 Coating Services Provided [YES / NO]
4 0 Welding Services Provided [YES / NO]
5 0 Soldering Services Provided [YES / NO]
"'YES" / "NO"
"'YES" / "NO"
IF YOU HAVE ANSWERED "NO" TO ANY OF THE QUESTIONS BELOW IN CELLS C3, C4, OR C5, PLEASE CLICK THE "NO" BUTTON FOR THAT LINE. THIS WILL ELIMINATE THE SPECIAL PROCESSES WORKSHEET
ATTACHED! THIS WILL REDUCE THE OVERALL SIZE OF THE WORKSHEET
Does this process require Heat Treat?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.
Does this process require Plating?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.
Does this process require Coating?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.
Does this process require Welding?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.
Does this process require Soldering?If "NO" Fill In and Then Click ButtonIf "YES" Fill in and Follow Directions Provided.
Cover PageCover Page
Index PageIndex Page