April 20, 2017 | Author: Armando Flores Moreno | Category: N/A
CQI-12v2 Special Process: Coating System Assessment
© 2012 Automotive Industry Action Group, except that copyright is not claimed as to any part of an original work prepared by a U.S. or state government officer or employee as part of the person’s official duties. Except as noted above, all rights are reserved by AIAG and no part of these materials may be reproduced, reprinted, stored in a retrieval system, or transmitted, in any form or by any means, electronic, photocopying, recording, or otherwise, without the prior written permission of Automotive Industry Action Group. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group. Automotive Industry Action Group makes no claim to any trademark of a third party. Trademarks of third parties included in these materials are the property of their respective owners © 2012 Automotive Industry Action Group © 2012 Automotive Industry Action Group
ISBN#: 978-1-60534-245-0-90000
CQI-12v2 Dated: 2/2012
1
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment 2nd Edition Facility Name: DeKalb Metal Finishing Address: 625 West 15th Street / PO Box 70 Auburn, IN 46706
Phone Number: 260-925-1820 Fax Number: 260-925-5258 Number of Coating Employees at this Facility: 43 Captive Plater (Y/N): NO Commercial Plater (Y/N): YES
Type(s) of Coating Processes at this Facility: Process Table A Pretreatment, Aqueous Process Table B Process Table C Process Table D
Date of Assessment: 1/1/2014 Process Table E Date of Previous Assessment: 1/1/2013 Process Table F Process Table G Process Table H Autodeposition Process Table I Cure Process Table J Process Table K Equipment Process Table L Part Inspection & Testing Current Quality Certification(s): ISO/TS 16949:2009 Date of Re-assessment (if necessary): Personnel Contacted: Name: Matt Morris
Title: Quality Manager
Phone: 260-925-1820 x114
Email:
[email protected]
Auditors/Assessors: Name: Matt Morris
Company: Quality Manager
Phone: 260-925-1820 x114
Email:
[email protected]
Number of "Not Satisfactory" Findings: 0
Number of "Needs Immediate Action" Findings: 0
Number of "Fail" Findings in the Job Audit(s): 0
Number of Process Table Items not meeting Minimum Requirements: 0
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.1
1.2
Is there a dedicated and qualified coating person onsite?
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 DeKalb Metal Finishing's Lab Manager position shall be reflected in the organization chart. A has more than 20 years of experience in job description shall exist identifying the qualifications the plating/surface finishing industry. for the position including chemical and coating The Job Description for the position of knowledge. The qualifications shall include a Lab Manager reflects this requirement. minimum of 5 years experience in coating operation or a combination of a minimum of 5 years of formal chemical education and coating experience.
X
Does the coater perform advanced quality planning?
The coater shall incorporate a documented advanced quality planning procedure. A feasibility study shall be DeKalb Metal Finishing uses the AIAG performed and internally approved for each new part manual as a reference for the creation or process. Similar parts can be grouped into part and implimentation of APQP's. In families for this effort as defined by the coater. After addition, we utilize Procedure 03 to the part approval process is approved by the further define our APQP policy. customer, no process changes are allowed unless Feasibility studies are done for each part approved by the customer. The coater shall contact and are maintained both in hard copy the customer when clarification of process changes is and electronic format. required. This clarification of process changes shall be documented.
X
© 2012 AIAG (Automotive Industry Action Group)
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.3
The coater 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 processAre the coater's FMEA's up to specific and written for each process. In any case, date and reflecting current they shall address all process steps from part receipt to part shipment and all key coating process processing? parameters as defined by the coater. A crossfunctional team shall be used in the development of the FMEA. All special characteristics, as defined by the coater and its customers, shall be identified, defined, and addressed in the FMEA.
DeKalb Metal Finishing uses the AIAG manual as a reference for the creation and implimentation of FMEA's. In addition, we utilize Procedure 03 to further define our FMEA policy. FMEAs are process specific.
X
1.4
The coater 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 DeKalb Metal Finishing uses the AIAG process. In any case, they shall address all process manual as a reference for the creation steps from part receipt to part shipment and identify all and implimentation of Control Plans. In equipment used and all key coating process addition, we utilize Procedure 14, to parameters as defined by the coater. A crossfurther define our Control Plan policy . Are finish process Control functional team, including a production operator, shall Control Plans are created electronically Plans up to date and reflecting be used in the development of Control Plans, which current processing? and are directly linked to our lab controls shall be consistent with all associated documentation in order to ensure that changes to the such as work instructions, shop travelers, and FMEAs. control plan are immediatly All special characteristics, as defined by the coater communicated to all affected parties. and its customers, shall be identified, defined, and Control Plans are process specific. 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.
X
© 2012 AIAG (Automotive Industry Action Group)
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
1.5
1.6
Question
Requirements and Guidance
Objective Evidence
N/A
1 - Management Responsibility and Quality Planning To ensure allSection customer requirements are both understood and satisfied, the coater 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 Chrysler. The coater shall Are all coating related and have a process to ensure the timely review, Yes, these documents are sent to us by referenced specifications distribution, and implementation of all customer and our customers. Additionally, we current and available? For industry engineering standards and specifications and subscribe to a service that notifies us example: SAE, AIAG, ASTM, changes based on customer-required schedule. This when specifications are updated. All General Motors, Ford, and process shall be executed as soon as possible and documents are controlled electronically Chrysler. shall not exceed two weeks. The coater shall in our document management software. document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the coater, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The coater 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 Job Setup Instructions are in place for process including relevant operating parameters. each part we produce. These Examples of operating parameters include process instructions include recommended cycle temperatures, cycle times, load rates, rectifier settings, times, recommended rectifier settings, etc. Such parameters shall not only be defined, they pieces per rack, racks per frame, shall have operating tolerances as defined by the required engineering specification, color, coater in order to maintain process control. All active thickness requirements, racking processes should have a written process specification. requirements, packaging requirements, These process specifications may take the form of and other special requirements, as work instructions, job card, computer-based recipes, defined by each customer. or other similar documents.
© 2012 AIAG (Automotive Industry Action Group)
Satisfactory
X
X
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.7
1.8
1.9
To demonstrate each process is capable of yielding acceptable product, the coater 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 coater 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 Has a valid product capability and in accordance with customer requirements. study been performed initially Capability study techniques shall be appropriate for and after process change? 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 coater 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? Are records available?
DeKalb Metal Finishing utilizes a combination of Procedure 10 and Procedure 28 to define and meet the specified requirements.
The analysis of products and processes over time can yield vital information for defect prevention efforts. The coater shall have a system to collect, analyze, DeKalb Metal Finishing uses an and react to product or process data over time. electronic system for gathering, storing, Methods of analysis shall include ongoing trend or and analyzing most types of data. This historical data analysis of special product or process data is analyzed on an ongoing basis to parameters. The coater shall determine which make decision on lab, production and parameters to include in such analysis. All process quality management. control and testing records must be retained for a minimum of one calendar year after the year in which they were created.
Are internal assessments The coater shall conduct internal assessments on an being completed on an annual annual basis, at a minimum, using the AIAG CSA. basis, at a minimum, Concerns shall be addressed in a timely manner. incorporating AIAG CSA?
© 2012 AIAG (Automotive Industry Action Group)
Requirement is met through completion of this survey.
X
X
X
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
1.10
Section 1system - Management The quality management shall include a Responsibility and Quality Planning 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 DeKalb Metal Finishing utilizes Is there a system in place to well as those characteristics for which reprocessing is Procedure 40 to manage the authorize reprocessing and is not permissible. All reprocessing activity shall require reprocessing. Referenced documents it documented? a new processing control sheet issued by qualified include Procedure 29 and Job Setup technical personnel denoting the necessary coating Instructions. 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.
1.11
Does the Quality Department review, address, and document customer and internal concerns?
1.12
DeKalb Metal Finishing has a three tier The coater shall define a process for continual (Red, Yellow, Green) process improvement for each coating process identified in the Is there a continual management system for controlling the scope of the CSA. The process shall be designed to improvement plan applicable plating process and measuring process bring about continual improvement in quality and to each process defined in the productivity. Identified actions shall be prioritized and improvement. This systems is monitored scope of the assessment? shall include timing (estimated completion dates). The as part of management review for coater shall show evidence of program effectiveness. effectiveness verification.
X
1.13
Does the Quality Manager or designee authorize the disposition of material from quarantine status?
X
The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the coater. A disciplined problem solving approach shall be used.
The Quality Manager or designee is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.
© 2012 AIAG (Automotive Industry Action Group)
DeKalb Metal Finishing utilizes an electronic system for recording and managing customer complaints and rejections.
The plant manager, in conjunction with the quality manager will determine the disposition of quarantined material.
X
X
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.14
Procedures, work instructions and other documentation are made available to all personnel through our electronic There shall be procedures or work instructions Document Management software. available to coating personnel covering the coating Specific documents include Procedure process. These procedures or work instructions shall Are there procedures or work 08 (Contingency Plans), Procedure 19 include methods of addressing potential emergencies (Inspection and Testing), DMFWI112 instructions available to (such as power failure), equipment start-up, equipment coating personnel that define (Plant Startup/Shutdown), DMFWI071 shut-down, product segregation (See 2.8), product the coating process? (Line 1 Startup), DMFWI072 (Line 1 inspection, and general operating procedures. These Shutdown), DMFWI073 (Line 2 Startup), procedures or work instructions shall be accessible to DMFWI074 (Line 2 Shutdown), shop floor personnel. DMFWI075 (Line 3 Startup), DMFWI076 (Line 3 Shutdown), DMFWI077 (Line 4 Startup), DMFWI078 (Line 4 Shutdown)
X
1.15
The coater shall provide employee training for all coating operations. All employees, including backup and temporary employees, shall be trained. DeKalb Metal Finishing educates Documented evidence shall be maintained showing employees on plating operations utilizing Is management providing the employees trained and the evidence shall include Program 1000 and Program 2000. employee training for coating? Documented evidence is maintained an assessment of the effectiveness of the training. electronically in Iour training software. Management shall define the qualification requirements for each function, and ongoing or followup training shall also be addressed.
X
1.16
Is there a responsibility matrix to ensure that all key management and supervisory functions are performed by qualified personnel?
The coater 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 coater). This matrix shall be readily available to management at all times.
© 2012 AIAG (Automotive Industry Action Group)
DeKalb Metal Finishing utilizes a Responsibility Matrix (DMF301) to ensure that all key management and supervisory functions are performed by qualified personnel.
X
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
1.17
1.18
Is there a preventive maintenance program? Is maintenance data being utilized to form a predictive maintenance program?
Has the coater developed a critical spare parts list, and are the parts available to minimize production disruptions?
The coater shall have a documented preventive maintenance program for key process equipment (as identified by the coater). 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.
DeKalb Metal Finishing utilizes a spreedsheet based maintenance log to manage its preventive / predictive maintenance program.
The coater shall develop and maintain a critical spare The critical spare parts list is included parts list and shall ensure the availability of such parts this in the maintenance log. to minimize production disruptions.
© 2012 AIAG (Automotive Industry Action Group)
X
X
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility andResponsibility Quality Planning Section 2 - Floor and Material Handling 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.
DeKalb Metal Finishings receiving documents (DMF114, DMF135, DMF250, or DMF324) are checked against customers incoming paperwork.
X
2.2
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. Customer product is typically identified Appropriate location and staging within the facility also by the customer on the packaging. help to ensure that orders are not shipped until all Additionally, DeKalb Metal Finishing required operations are performed. Customer product labels the product during the receiving shall be clearly identified and staged throughout the process. Once the plating process is coating process. Non-coated, in-process, and finished completed, plated parts are moved to the product shall be properly segregated and identified. All warehouse where they are placed with material shall be staged in a dedicated and clearly "finished goods". defined area.
X
2.3
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.
DeKalb Metal Finishing utilizes DMF114, DMF135, DMF250, or DMF324 to maintain lot integrity throughout all processes.
X
Are procedures adequate to prevent movement of nonconforming 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 DeKalb Metal Finishing utilizes adequate to prevent movement of non-conforming Procedure 29 to manage the integrity of product into the production system. Procedures shall the non-conforming / hold area to unsure exist addressing proper disposition, product segregation of such material. 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.
X
2.1
2.4
© 2012 AIAG (Automotive Industry Action Group)
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
2.5
2.6
2.7
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
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 DeKalb Metal Finishing has identified identify and monitor trap points for each trap points and posted these findings on process/equipment. Monitoring of potential trap points signage located throughout the plant. shall occur for every part changeover.
X
Are containers free of inappropriate material?
Containers handling customer product shall be free of inappropriate material. After emptying and before reusing 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.
DeKalb Metal Finishing uses customer supplied containers.
X
DeKalb Metal Finishing utilizes Job Setup Instructions to specify loading parameters. These documents are controlled electronially.
X
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.
2.8
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 DeKalb Metal Finisng trains operators on including power failure. Training shall be documented. material handling, containment, and Work instructions specifically addressing potential product segrigation. This training is types of equipment emergencies and failures shall be verified through the use of our procedure accessible to and understood by equipment operators. quiz (DMF268). These instructions shall address containment/reaction plans related to all elements of the process. Evidence shall exist showing disposition and traceability of affected product.
X
2.9
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 quality concerns.
X
© 2012 AIAG (Automotive Industry Action Group)
DeKalb Metal Finishing utilizes Procedure 18 to ensure preservation of product.
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
2.10
Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling Are plant cleanliness, and improving quality. The coater should evaluate housekeeping, environmental such conditions and their effect on quality. A and working conditions housekeeping policy shall be clearly defined and conducive to control and executed. The facility shall be reviewed for the improved quality? following items: loose parts on floor; spillage around tanks; overall plant lighting; fumes etc.
2.11
Are process control parameters monitored per frequencies specified in Process Tables?
2.12
Cotrol points are identified and reviewed There are documented reaction plans to both out of electronically. When a control point Are out of control/specification control and out of tolerance process parameters. falls outside the specified range, affected parameters reviewed and parties are electronically notified and There is documented evidence that reaction plans are reacted to? action is taken to ensure the control followed. point is restored to appropriate levels.
X
2.13
Are In-Process / Final Test Frequencies performed as specified in Process Tables?
The resulting data from in process inspection is stored electronically in an SQL database. The resulting datea from final inspection is stored electronically in our Final Audit Log spreadsheet.
X
DeKalb Metal Finishing utilizes gage calibration software to log and monitor calibrations as well as MSA studies.
X
2.14
Is product test equipment verified?
DeKalb Metal Finishing utilizes Procedure 09, DMF194, and DMF253 to manage facility cleanliness. Procedure 09 and DMF194 manage general plant cleanliness while DMF253 relates to building maintenance.
X
Process control parameters shall be monitored per Process parameters are created, frequencies specified in Process Tables. Computer monitored, and logged electronically and monitoring equipment with alarms and alarm logs are directly linked to the control plans. satisfy the verification requirement. A designated floor This ensures that changes made to the person shall verify the process parameters, e.g., by control plan are communicated to all initialing a strip chart or data log. affected parties immediately.
X
In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables.
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.
© 2012 AIAG (Automotive Industry Action Group)
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Special Process: Coating System Assessment (General Facility Overview)
Assessment
Question Number
Question
Requirements and Guidance
Objective Evidence
N/A
Satisfactory
Section 1 - Management Responsibility and Quality Planning
Is lighting of inspection area adequate?
Lighting in the inspection area must be sufficient to allow the evaluation of all part surfaces. The lighting shall be arranged to preclude spot lighting, glare or shadows. There can be no moving or distracting reflections on the surfaces to be evaluated.
Lighting is adequate
X
2.16
Are the water rinse Control Plans up to date and reflect best case practices?
Identify operating parameters including: - number of rinse tanks between process stages, - tank type (single rinse, counter flowing, stationary rinse, spray rinse) - flow rate, - water requirements (city or deionized water, reverse osmosis), - filtration (if applicable) - control methods - temperature (if applicable)
Water Rinses are listed on the Control Plans
X
2.17
Aware of water quality and it's impact on each specific Is the water quality adequate? process. Purified water is used where necessary, or where specified.
DI Water used after paint.
X
2.15
© 2012 AIAG (Automotive Industry Action Group)
Not Satisfactory
Needs Immediate Action
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat Related CSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
3.1
Is contract review and advanced quality planning, FMEA, Control Plans, etc., performed by qualified individuals?
1.1 1.2 1.3 1.4 1.6
Yes
N/A
Sales Manager, Lab Manager, Quality Manager
P
3.2
Does the coater have the proper customer specifications for the part?
1.5
Yes
N/A
No Coating Spec on Print. ASTM B117 for NSS
P
3.3
Is a shop traveler created to meet customer requirements?
1.6 2.1
Yes
Final Audit Log, DMF114, DMF135, DMF250
DMF250
P
3.4
Is material identification (part numbers, lot numbers, contract numbers, etc.) maintained throughout the coating process?
2.2 2.3 2.4
Yes
Final Audit Log, DMF114, DMF135, DMF250
DMF250
P
3.5
Is there documented evidence of Receiving Inspection?
2.1
Yes
Certificate of Analysis, DMF114, DMF135, DMF250
3.6
Are the Loading / Racking requirements identified?
1.6 2.7 2.9
Yes
Rack Number and Packing Method Identified on DMF147
Question #
Job Audit Question
© 2012 AIAG (Automotive Industry Action Group)
Reviewed as part of receiving inspection, DMF250 All racks are identified by rack number in system (D-16)
P
P
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question #
Job Audit Question
Related CSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
3.7
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.
1.5 1.6 2.1 2.11 2.13
Yes
Control Plans
ControlPlan03
P
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question #
Job Audit Question
3.8
What are the product inspection requirements?
3.8.1
Requirement: Coating Thickness Test Method: Test frequency or quantity:
3.8.2
Related CSA Question # 1.5 2.13
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Each part may have one or more requirements determined by the coating specification. Parts must meet each requirement. List each requirement below and validate. 2.14 (Listed below are some examples) .00049 - .00070 Dualscope Internal
Selection of samples: Specification:
Internal GM9984132
Requirement: Corrosion Resistance (if applicable)
168hrs - No Red
Test Method(s):
ASTM B117
Test frequency or quantity:
As Required by Customer
DMF147, DMF114, DMF135, DMF250 First 6, one per hour, last 6 Random
DMF147, DMF114, DMF135, DMF250 First 6, one per hour, last 6 Random
3.8.3
© 2012 AIAG (Automotive Industry Action Group)
P P P
Panel
Panel
P P P
No Spec on Print
Requirement: Hydrogen Embrittlement Relief (if applicable) Test Method:
P
P
Selection of samples: Specification:
Pass / Fail / N/A
N/A
240hrs No Red
Parts meet spec
P
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question #
3.8.4
Job Audit Question
N/A
Selection of samples:
N/A
Specification:
N/A
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Requirement: Adhesion Tape Test Internal
ISOSystem First 6, one per hour, last 6
Selection of samples:
Internal
Random
Specification:
No Spec on Print
Test frequency or quantity:
3.8.6
Customer or Internal Requirement
Test frequency or quantity:
Test Method(s):
3.8.5
Related CSA Question #
Requirement: Cure Test Method:
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
Specification:
N/A
Requirement: Torque Tension (if applicable) Test Method:
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
© 2012 AIAG (Automotive Industry Action Group)
ISOSystem First 6, one per hour, last 6 Random
P P P P
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question #
3.8.7
3.8.8
3.8.9
Job Audit Question
Related CSA Question #
Customer or Internal Requirement
Specification: Requirement: Appearance (Decorative) Test Method:
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
Specification: Requirement: Dimensional (if applicable) Test Method:
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
Specification: Requirement: Color and Gloss (Decorative) Test Method:
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
Specification:
N/A
© 2012 AIAG (Automotive Industry Action Group)
N/A
N/A
N/A
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question # 3.8.10
Job Audit Question
Related CSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Yes
DMF114, DMF135, DMF250
Verified on DMF250 and Final Audit Log
P
Yes
ISOSYSTEM
Verified inspection records on ISOSYSTEM
P
Requirement: Customer Specific Test Method(s):
N/A
Test frequency or quantity:
N/A
Selection of samples:
N/A
Specification:
N/A
Operator or Inspector Responsibilities
3.9
Were appropriate process steps signed off?
1.4 1.6 2.2 2.3 2.11
3.10
Were all inspection steps, as documented in the Control Plan performed?
1.2 1.4
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat Job (Shop) Order or Reference Documentation Requirement
Question #
Job Audit Question
Related CSA Question #
Customer or Internal Requirement
3.11
Were steps/operations performed that were not documented in the Control Plan?
1.2 1.4 1.6
No
P
3.12
If additional steps were performed, were they authorized?
1.2 1.4 1.6 1.10 1.16
N/A
P
3.13
Does the governing specification allow reprocessing or rework?
1.5 1.10
Not referenced
P
3.14
If the order was certified, did the certification accurately reflect the process performed?
2.11 2.13
N/A
P
3.15
Was the certification signed by an authorized individual?
1.16
N/A
P
3.16
Are the parts and containers free of inappropriate objects or contamination?
2.6
Yes
© 2012 AIAG (Automotive Industry Action Group)
Actual Condition (Objective Evidence)
No foreign objects in container
Pass / Fail / N/A
P
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
Section 3 - Job Audit - Finished Product Review Job Identity: Customer: ZF Lemforder Shop Order Number: 010713-03-37 Part Number: 734.178.135.453 Part Description: Bushing Coating Requirements: No Spec for A-Coat
Question #
Job Audit Question
Related CSA Question #
Customer or Internal Requirement
Job (Shop) Order or Reference Documentation Requirement
Actual Condition (Objective Evidence)
Pass / Fail / N/A
Packaging Requirements 3.17
Are packaging requirements identified?
2.6 2.7 2.9
Yes
DMF147
3.18
Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?
2.6 2.7 2.9
Yes
DMF147
Verified parts were packaged acording to DMF147 Parts packed in customer suppled cardboard boxes exaxtly as they have requested. To reduce the risk of mixed parts, lids on customer provided boxes must be closed and taped shut before parts can be moved from the production to shipping.
P
P
Shipping Requirements 3.19
Were the parts properly identified?
2.3 2.9
Yes
Verified DMF250
P
3.20
Were the containers properly labeled?
2.3 2.9
Yes
No labeling requirements
P
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Category/Process Steps
Type of Control Minimum Requirement
1.0 A1.1
A1.2
Actual Condition
Monitoring Frequency
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
AQUEOUS CLEANING PROCESS (Alkaline or Acid) 1.4
1.4 1.6 2.11 2.12
There shall be an incoming part assessment procedure Per Control Plan with criteria.
Time
Automatic/Manual
Per Control Plan
Automatic
Once per lot and per part change
Pass
Automatic Line: Confirm set-up at the start of production and every process change. Manually verify every 3 months or after programming change or equipment Time cannot be adjusted maintenance. Manual Line: Continuously monitor time in each stage of process.
© 2012 AIAG (Automotive Industry Action Group)
Once per lot and per part change
Pass
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 2.0 A2.1
A2.2
1.4 2.11 2.12
Temperature
A2.3
1.4 1.6 2.11 2.12
Chemical Concentration (Alkaline Cleaner) (If used) Per chemical supplier recommendation such as: - free alkalinity - total alkalinity - pH - conductivity - percentage of cleaner (weight/volume or volume/volume)
A2.4
1.4 1.6 2.11 2.12
Chemical Concentration (Acid Cleaner) (If used) Per chemical supplier recommendation such as: - free acidity or concentration - metal contamination
Automatic/Manual
1.4 2.11 2.12
Impurity Content Per chemical supplier recommendation such as: - acid split (oil contamination) - alkalinity ratio
Manual
2.11
There is a tank maintenance schedule for cleaning baths.
A2.6
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Cleaning / Descaling Solution 1.4 2.11 2.12
A2.5
Actual Condition
Monitoring Frequency
Pressure for spray rinse. Agitation for immersion tanks.
Automatic/Manual
Once every 8 hours
Automatic
Continuous monitoring by controller. Manually verify daily.
Pass
© 2012 AIAG (Automotive Industry Action Group)
Automatic/Manual
Manual
Once every 4 hours Pass
Manual
For continuous operations, once per day. Otherwise, prior to start of each Once per day production cycle.
Manual
For continuous operations, once per day. Otherwise, prior to start of each production day. (once per day for Once per day concentration, once per month for contamination).
Pass
Manual
Once per week*
Once per week
Per preventative maintenance program
Frequencey driven by lab data.
Pass
Pass Manual
Manual
Pass
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 3.0
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Rinse(s)
A3.1
1.4 2.11 2.12
Pressure for spray rinse. Agitation or flow for immersion tanks.
Automatic/Manual
A3.2
1.4 2.11 2.12
Temperature (if controlled)
Automatic
1.4 2.11 2.12
Cleanliness of last cleaner rinse - alkalinity/pH/conductivity - visual inspection for oil or suspended contaminants - overflow
A3.3
Actual Condition
Monitoring Frequency
N/A
Once every 8 hours
N/A Pass
N/A
Continuous monitoring by controller. Manually verify once per day.
N/A Pass
Manual
Manual
Once per day
Once per day Pass
A3.4
2.11
There is a dump schedule for rinses.
Manual
Automatic
A3.5
1.4 2.11
There is a visual inspection (e.g. water break) after each post cleaning rinse bath (not applicable for closed Manual barrel systems).
N/A
A3.6
1.4 2.11
Corrosion inhibitor concentration is checked. (If used)
N/A
Per preventative maintenance schedule.
Running Rinse Pass
© 2012 AIAG (Automotive Industry Action Group)
Automatic/Manual
Once every 8 hours
N/A Pass
Once every 8 hours
N/A
Pass
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 4.0
A4.1
A4.2
A4.3
A4.4
Actual Condition
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Acid Pickling 1.4 2.11 2.13
Concentration
1.4 2.11 2.12
Concentration of Fe, per coating supplier.
1.4 2.11 2.12 1.4 2.11 2.12
A4.5
Manual
N/A
Once every 8 hours
N/A Pass
Manual
N/A
Once per day
N/A Pass
Inhibitor (if used)
Manual
N/A
N/A
N/A Pass
Solution Level
Manual
N/A
Once every 8 hours
N/A Pass
Rinse - See Section 3.0.
5.0
Aluminum Etching
A5.1
1.4 2.11 2.12
Concentration
A5.2
1.4 2.11 2.12
Concentrations of Al, per coating supplier.
A5.3
Monitoring Frequency
Manual
N/A
Once every 8 hours
N/A Pass
Manual
N/A
Once per day
N/A Pass
Rinse - See Section 3.0.
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 6.0
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Aluminum Deoxidizing
A6.1
1.4 2.11 2.12
Concentration
A6.2
1.4 2.11 2.12
Concentrations of Al, per coating supplier.
A6.3
Manual
N/A
Once every 8 hours
N/A Pass
Manual
N/A
Once per day
N/A Pass
Rinse - See Section 3.0. Sealing Rinse (if applicable)
7.0 A7.1
1.4 2.11 2.13
Temperature (if applicable)
A7.2
1.4 2.11 2.12
Concentration
A7.3
1.4 2.11 2.12
Solution Level
A7.4
Actual Condition
Monitoring Frequency
Automatic
N/A
Manually measure once every 8 hours
N/A Pass
Manual
N/A
Once every 8 hours
N/A Pass
Manual
N/A
Once every 8 hours
N/A Pass
Rinse - See Section 3.0.
© 2012 AIAG (Automotive Industry Action Group)
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
PROCESS TABLE H - Autodeposition 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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 1.0 1.4 2.11 2.12
Mixer speed and direction are monitored and adjusted.
Automatic/Manual
H1.2
1.4 1.6 2.11 2.12
Temperature of the coating bath is continuously monitored and controlled.
Automatic
H1.3
1.4 2.11 2.12
Misting nozzles in the vicinity of the coating bath are operational.
Automatic/Manual
H1.4
1.4 2.11 2.12
Acid (e.g., 101 meter) and oxidation/reduction potential (ORP) levels are checked.
Automatic/Manual
H1.6
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Coating Bath
H1.1
H1.5
Actual Condition
Monitoring Frequency
1.4 2.11 2.12 1.4 1.17 2.11 2.12
Manual
Once every 8 hours Ongoing
Manual
Continuous monitoring by controller and manually verified once per day.
Pass
Once every 4 hours Pass
Manual
Once every 8 hours Pass
Manual
Once every 2 hours
Once every 2 hours Pass
Chemical concentration (% solids, starter/iron Automatic/Manual titration, conductivity) is checked and maintained.
Manual
Coating tank, mixers and heating/cooling system Manual are inspected and maintained.
Manual
© 2012 AIAG (Automotive Industry Action Group)
Once every 8 hours
Once every 8 hours
Once every 24 hours Pass
Once every 12 months
As needed Pass
CQI-12
Special Process: Coating System Assessment Version 2 Issued 2/2012
PROCESS TABLE H - Autodeposition 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.
*If minimum requirements are not met, provide supporting records to justify actual conditions.
Item #
Related CSA Question #
Type of Control
Category/Process Steps
Minimum Requirement 2.0
Minimum Requirement
Observation/Comments
Actual Condition
(Pass / Fail / N/A)
Tap Rinse After Coating
H2.1
1.4 2.11 2.12
Pump pressure or agitator speed is monitored.
H2.2
1.4 2.11 2.12
Impurity concentration (conductivity) is checked.
3.0
Automatic/Manual
N/A
Once every 8 hours
N/A Pass
Automatic/Manual
Manual
Once every 8 hours
Once every 24 hours Pass
Reaction Rinse
H3.1
1.4 2.11 2.12
Chemical concentration is checked and maintained.
Automatic/Manual
H3.2
1.4 2.11 2.12
Pump pressure or agitator speed is monitored.
Automatic/Manual
H3.3
1.4 2.11 2.12
Temperature is monitored and controlled if required by chemical manufacturer's technical data sheet.
Automatic/Manual
H3.4
1.4 1.17 2.11 2.12
There is a dump schedule.
Manual
4.0
Actual Condition
Monitoring Frequency
Manual
Once every 8 hours
Once every 24 hours Pass
N/A
Once every 8 hours
N/A Pass
N/A
Once every 8 hours
N/A Pass
Manual
Per Chemical Manufacturer's recommendation and production volume.
Once per week Pass
Cure (See Cure Process Table I)
© 2012 AIAG (Automotive Industry Action Group)
