Home >Documents >Supplier Evaluation (QVR)Rev6 0112

Supplier Evaluation (QVR)Rev6 0112

Date post:27-Dec-2015
Category:
View:241 times
Download:26 times
Share this document with a friend
Description:
For new Business
Transcript:

Supplier Quality System QVR Survey

INDEXSupplier Evaluation / QVR AssessmentWorkbook IndexlDocument Change SummarylInstructionslQVR / Supplier Evaluation ScoringlQVR Process MaplCover (sheet)lSupplier Evaluation SummarylQualitylDeliverylSupport & TechnologylCostlPrint ReviewSpecial Processes: AIAGCQI-9 Heat Treat System AssessmentCQI-11 Plating System AssessmentCQI-12 Coating System AssessmentlCQI-9 Instructions for Cover SheetlCQI-11 Instructions for CoverlCQI-12 Cover Sheet Instrts.lCQI-9 Cover SheetlCQI-11 Cover SheetlCQI-12 Cover SheetlCQI-9 Elements, Sec. 1-3lCQI-11 Sections 1 & 2 GenerallCQI-12 Section 1 & 2 GenerallCQI-9 Job Audit, Sec. 4lCQI-11 Sect. 3 ZN-ZN Alys. Eq.lCQI-12 Job AuditlCQI-9 Assessor's Qual. Reqs..lCQI-11 Section 4-DECO Equip.lCQI-12 Assessor's Quals.lCQI-9 Process Table AlCQI-11 Section 5 Job AuditlCQI-12 Process Table AlCQI-9 Process Table BlCQI-11 Assessor's Quals.lCQI-12 Process Table BlCQI-9 Process Table ClCQI-11 Process Table AlCQI-12 Process Table ClCQI-9 Process Table DlCQI-11 Process Table BlCQI-12 Process Table DlCQI-9 Process Table ElCQI-11 Process Table ClCQI-12 Process Table ElCQI-11 Process Table DlCQI-12 Process Table FlCQI-11 Process Table ElCQI-12 Process Table GlCQI-11 Process Table FlCQI-12 Process Table HlCQI-12 Process Table IlCQI-12 Process Table JCQI-15 Welding System AssessmentCQI-17 Soldering System AssessmentlCQI-15 Cover Sheet InstrtslCQI-17 Cover Sheet Instrts.lCQI-15 Cover SheetlCQI-17 Cover SheetlCQI-15 Elements Section 1 - 5lCQI-17Sect. 1&2 - Gen. OverviewlCQI-15Job Audit Section 6 Proc.lCQI-17 Section 3 - EquipmentlCQI-15 Arc Welding Table AlCQI-17Section 4 - Job AuditlCQI-15 Resist.Welding Table BlCQI-17Proc. Tab. A Paste Print.lCQI-15 Laser Welding Table ClCQI-17 Process Table B Insp.lCQI-15Solid State Weld. Table DlCQI-17Proc. Tab. C Surface MntlCQI-17 Proc. Table D ReflowlCQI-17 Proc. Table E Glue Disp.lCQI-17 Proc. Table F FluxlCAI-17 Proc. Table G Pre-HeatlCQI-17 Proc.Table H WavelCQI-17 Proc. Table I FountainlCQI-17Proc. Tab.J Dip SolderinglCQI-17Proc Tab. K Select. Sold.lCQI-17Tab. L Auto Iron SoldinglCQI-17Tab. M Man.l Iron SolderlCQI-17Tab. N Laser & Soft BeamlCQI-17 Tab. O InductionlCQI-17Tab. P Conform. Coat&TstlCQI-17 Tab. Q PCB SeperationlCQI-17Tab. R In-circuit TestinglCQI-17 Tab. S Re-work

InstructionsDocument Change SummaryCover (sheet)Supplier Evaluation SummaryQualityDeliverySupport & TechnologyCostQVR / Supplier Evaluation ScoringPrint ReviewCQI-9 Instructions for Cover SheetCQI-9 Cover SheetCQI-9 Elements, Sec. 1-3CQI-9 Job Audit, Sec. 4CQI-9 Assessor's Qual. Reqs..CQI-9 Process Table ACQI-9 Process Table BCQI-9 Process Table CCQI-9 Process Table DCQI-9 Process Table ECQI-11 Instructions for CoverCQI-11 Cover SheetCQI-11 Sections 1 & 2 GeneralCQI-11 Sect. 3 ZN-ZN Alys. Eq.CQI-11 Section 4-DECO Equip.CQI-11 Section 5 Job AuditCQI-11 Assessor's Quals.CQI-11 Process Table ACQI-11 Process Table BCQI-11 Process Table CCQI-11 Process Table DCQI-11 Process Table ECQI-11 Process Table FCQI-12 Cover Sheet Instrts.CQI-12 Cover SheetCQI-12 Section 1 & 2 GeneralCQI-12 Job AuditCQI-12 Assessor's Quals.CQI-12 Process Table ACQI-12 Process Table BCQI-12 Process Table CCQI-12 Process Table DCQI-12 Process Table ECQI-12 Process Table FCQI-12 Process Table GCQI-12 Process Table HCQI-12 Process Table ICQI-12 Process Table JQVR Process MapDocument Change SummaryCQI-15 Cover SheetCQI-15 Elements Section 1 - 5CQI-15Job Audit Section 6 Proc.CQI-15 Arc Welding Table ACQI-15 Resist.Welding Table BCQI-15 Laser Welding Table CCQI-15Solid State Weld. Table DCQI-17 Cover Sheet Instrts.CQI-17 Cover SheetCQI-17Sect. 1&2 - Gen. OverviewCQI-17 Section 3 - EquipmentCQI-17Section 4 - Job AuditCQI-17Proc. Tab. A Paste Print.CQI-17 Process Table B Insp.CQI-17Proc. Tab. C Surface MntCQI-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 SolderCQI-17Tab. N Laser & Soft BeamCQI-17 Tab. O InductionCQI-17Tab. P Conform. Coat&TstCQI-17 Tab. Q PCB SeperationCQI-17Tab. R In-circuit TestingCQI-17 Tab. S Re-workCQI-15 Cover Sheet Instrts

Chg SmryIndexSupplier Evaluation (QVR) Change Summary (Rev. 6.0)Rev. 1A. PROCESS MAP:09/10/20091Changed to Input-Process-Output (IPO) type format. Provided additional clarity to a couple of steps of the process.B. SUPPLIER ASSESSMENT WORKSHEET1Entire Supplier Evaluation is segregated into 4 key critical areas: Quality, Delivery, Support & Technology, and Cost .2Counter 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.3There 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, 2010.4A button has been added to take you directly to the AIAG Special Processes worksheets. By clicking 'YES" on the "COVER PAGE" youwill 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 notbe required. This also reduces the size of the Supplier Evaluation / QVR Worksheet.5Have 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".6You 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.7A 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%.C. COVER PAGE: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 'ManufacturingSite' 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 maybe overwritten as needed.D. PARAMETERS FOR WORKSHEET: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.Rev. 2Revised to clarify language and responsibility (Process Map), and add Enviromental elements back in (omitted with Rel. 1.2)10/28/2009Rev. 3Revised to add requirement for 'All applicable issues identified" to be resolved (closed) PRIOR to Sourcing on 'Instructions' and 'QVR Scoring Key' worksheets.04/20/2010Rev.4Revised all sections. If any individual line item is < 7 that sub-section and ultimately the entire QVR will display a "FAILED" Status.06/09/2010Rev.5Amended with New AIAG Special Process Worksheets CQI-15 Welding Systems Assessment and CQI-17 Soldering Systems Assessment.07/19/2010Eliminated Individual Section Findings Sheets. Enlarged SDE Comments on individual sections.Rev. 6.0Also added print areas to 4 Critical areas.05/27/2011Changed Question Q. 1.1 to reflect TS-16949 Certification.Changed Q3.3 to accept NO as a positive answer and Yes as a negative.Minor language changes have been made to the following sections and subsections to enhance understanding:C 3.1.1, C 3.4.1, C 3.5.1, C 3.7.1, C 4.1.1, C 4.2.1, and S 3.2.1.

Cover PageIndex PageIndex

InstructionsIndexSupplier Evaluation (QVR) OverviewPurpose: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.Application: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.Instructions:A general overview of the process is illustrated on the next worksheet of this file; referencePrior 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).Note: For Remy internal use, refer to RCP-741 QVR Survey Letter.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 5-10 PSI.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E3.61.4 2.11 2.12Flow direction is checked (for monorail system).ManualPer Control Plan/Log Sheet (1/shift minimum)E3.71.4 2.11 2.12Flow over the weir is checked.ManualPer Control Plan (1/shift minimum)E3.81.4 2.11 2.12Bath is checked for microbial contamination.ManualPer Control Plan/Log Sheet (1/ per week minimum)E3.91.4 2.11 2.12Incoming DI / RO water is checked for cleanliness. (conductivity)Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E3.101.41.172.112.12Paint racks are being maintained.Automatic/ManualAs neededE3.111.41.172.112.12There is a paint rack maintenance schedule.ManualRequiredE3.121.41.172.112.12There is a tank clean up schedule.ManualRequired (1/year minimum)4.0Anolyte SystemE4.11.4 2.11 2.12The anolyte solution is being controlled within the required conductivity limits.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E4.21.4 2.11 2.12The conductivity reading on the anolyte tank has been confirmed in the laboratory.Automatic/ManualPer Control Plan/Log Sheet 1 / weekE4.31.4 2.11 2.12The pH of the anolyte solution has been checked.Automatic/ManualPer Control Plan/Log Sheet (1 per shift)E4.41.4 2.11 2.12Anodes have been inspected.ManualPer Control Plan/Log Sheet (1 per six months)E4.51.4 2.11 2.12The anolyte solution is being circulated to each cell.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E4.61.4 2.11 2.12Dump and clean schedule for anolyte being maintained.ManualPer Control Plan/Log SheetE4.71.4 2.11 2.12Amperage draw has been checked on each anode.Automatic/ManualPer Control Plan/Log Sheet5.0RectifierE5.11.41.62.112.12The proper voltage is being used for the load size.Manualper Equip. Mfg.E5.21.4 2.11 2.12The ramp up time to full voltage has been verified.Automatic/ManualPer Control Plan/Log Sheet (1 per shift)E5.32.10There is a safety beacon to alert personnel when system is energized.E5.41.41.172.112.12The ripple of the rectifier has been checked by an approved electrician.Automatic/ManualPer Control Plan / material supplier6.0Rinse SystemE6.11.4 2.11 2.12Immersion rinse tanks are operating at the proper levels and tanks are being agitated correctly.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E6.21.4 2.11 2.12There is sufficient permeate supplied to the rinse.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E6.31.4 2.11 2.12The pH and conductivity of the rinse have been recorded.ManualPer Control Plan/Log Sheet (1/shift minimum)E6.41.4 2.11 2.12There is microbial testing of rinses.ManualPer Control Plan / material supplierE6.51.4 2.11 2.12The ultrafilters are operating at proper pressures and bag filters are being used. What size bags?Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)E6.61.41.172.112.12Rinses have been cleaned per maintenance schedule.ManualPer Control Plan / material supplier7.0Cure (See Convective Cure Process Table I)

Index PageCover Page

CQI-12 PROCESS TABLE FPROCESS TABLE F - SprayAll 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.Item #Related CSA Question #Category/Process StepsControlMonitoring1.0Part AppearanceF1.11.4 2.11Incoming parts are inspected for cleanliness, trapped water or water spots as well as uniform phosphate coating (when phosphate is used).ManualPer Control Plan/Log Sheet (1 per hour)F1.21.14Inspection criteria are posted.F1.32.10Adequate lighting is in place.F1.41.4 2.9Mutilation prevention items (i.e. gloves, belt buckle covers, watch covers, etc.) are in place.F1.51.41.172.112.12Paint racks are maintained.Manual2.0Paint MixingF2.11.4 2.11 2.12Paint mixing rooms are controlled (mixing tank grounding, closed container, properly enclosed space, temperature, clean environment).Automatic/ManualPer Paint Manufacturer RecommendationF2.21.4 2.11 2.12FIFO system is being utilized.ManualPer Paint Manufacturer RecommendationF2.31.4 1.6 1.17 2.11 2.12Paint agitation/time and reduction (solvent package) are proper and documented.ManualPer Paint Manufacturer RecommendationF2.41.4 1.6 1.17 2.11 2.12Viscosity and temperature are in operational limits and documented.ManualPer Control Plan/Log Sheet/Paint Manufacturer RecommendationF2.51.4 1.6 1.17 2.11 2.12The proper filter size and type are in place.ManualPer Control Plan/Log Sheet/Paint Manufacturer RecommendationF2.61.4 1.6 1.17 2.11 2.12Pump pressures are set within operational limits.ManualPer Control Plan/Log Sheet/Paint Manufacturer RecommendationF2.71.4 2.11 2.12Circulation (flow meter, pressure gage) is monitored.Automatic/ManualPer Control Plan/Log SheetF2.81.4 2.11 2.12Bag filter pressures are monitored (bags are changed when psi differential >5-10 PSI).Automatic/ManualPer Control Plan/Log Sheet3.0Substrate Conditioning (Flame, Plasma, etc) (If applicable)F3.11.4 2.11Incoming parts are inspected to ensure that they are free of dirt and contamination.ManualF3.21.4 1.17 2.11 2.12Flame/Plasma is set at operational limits per equipment and material supplier recommendations.AutomaticPer control plan and equipment and substrate suppliers recommendationsF3.31.4 2.11 2.13Final surface tension is within specifications.ManualPer Control Plan4.0Primer/PromoterF4.11.4 2.11Incoming parts are inspected to ensure that they are free of dirt and contamination.ManualPer Control Plan/Log Sheet (1/shift minimum)F4.21.41.172.112.12Destaticizing air is operational. (Plastic parts only)AutomaticPer Control Plan/Log Sheet 1 / weekF4.31.4 2.11 2.12Booth balance is monitored.ManualPer Control Plan/Log Sheet 1 / weekF4.41.4 1.6 1.17 2.11 2.12Booth temperature and humidity are monitored (or set within operational limits if controlled).Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)F4.51.4 2.11 2.12Film thickness is per customer requirements.ManualPer control plan and customer requirementsF4.61.4 1.6 1.17 2.11 2.12Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.Automatic/ManualPer Control Plan/Log Sheet (1 per month minimum)5.0Basecoat (If applicable)F5.11.4 2.11Incoming parts are inspected to ensure that they are free of dirt and contamination.ManualPer Control Plan / material supplier (once per shift minimum)F5.21.4 1.6 2.11 2.13Flashtimes between coats are set at suppliers recommended times.Automatic/ManualPer Control Plan/material supplierF5.31.4 1.6 1.17 2.11 2.12Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)F5.41.4 1.6 1.17 2.11 2.12Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.Automatic/ManualPer Control Plan/Log Sheet (1 per month minimum)F5.51.4 2.11 2.13Film builds are per supplier recommendations.ManualPer Control Plan and suppliers recommendations6.0Basecoat Heated Flash (Waterborne Materials Only)F6.11.4 1.6 2.11 2.13Set point is at suppliers recommended time, temperature and energy type (convection/IR/UV/etc.).ManualPer Control Plan / material supplierF6.21.4 1.6 2.11 2.13Percent solids after pre-dry is at the suppliers recommended percentage.ManualPer Control Plan/Log Sheet (1/shift minimum)F6.31.41.172.112.12The pre-dry oven is maintained.ManualPer Control Plan / material supplier7.0ClearcoatF7.11.4 2.11Incoming parts are inspected to ensure that they are free of dirt and contamination.ManualPer Control Plan / material supplier (once per shift minimum)F7.21.4 1.6 2.11 2.13Flashtimes between coats are set at suppliers recommended times.Automatic/ManualPer Control Plan/material supplierF7.31.4 1.6 1.17 2.11 2.12Booth temperature and humidity are monitored or set within operational limits if controlled. (Required for waterborne coatings)Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)F7.41.4 1.6 1.17 2.11 2.12Atomizer parameters (fluid flow, air pressures (atomizing fan, shaping), electrostatics and mixing) are set within operational limits.Automatic/ManualPer Control Plan/Log Sheet (1 per month minimum)8.0Cure (See Convective Cure Process Table I)9.0Final Part InspectionF9.11.14Inspection criteria are posted.F9.22.10There is adequate lighting in inspection area.F9.31.4 2.9Mutilation prevention items are in place.F9.41.4 1.8 1.12 2.13Defects are being tracked.ManualPer Control PlanF9.51.4 2.13FTT is being monitored.ManualPer Control PlanF9.61.10 1.11 1.12Scrap and repaints are being tracked.ManualPer Control Plan

Index PageCover Page

CQI-12 PROCESS TABLE GPROCESS TABLE G - Dip/SpinAll 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.Item #Related CSA Question #Category/Process StepsControlMonitoring1.0Coating Material ApplicationG1.11.4 2.11After pretreatment, parts are inspected for flash rust, wetness, oil or other defects.ManualPer Control Plan/Log Sheet (each lot)G1.21.4 2.11If phosphated, parts are checked for uniformity of phosphate coating.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)G1.32.6 1.17Skids/bins used to hold parts between coating operations are free of oil, grease or other contaminants.ManualPer Control Plan/Log Sheet (each lot)2.0Coating BathG2.11.4 2.11 2.12Incoming paint viscosity is checked.ManualEach New Lot of PaintG2.21.4 2.11 2.12Incoming solids checks are performed.ManualEach New Lot of PaintG2.31.41.172.112.12Appropriate mixing equipment is used, capable of dispersing settled solids.ManualOngoingG2.42.9 2.10Paint is stored properly, away from high humidity and temperature extremes.ManualOngoingG2.52.9 2.10Paint is kept covered and/or sealed when not in use.ManualOngoingG2.62.9 2.10Paint storage room is organized so each paint is easily found to prevent contamination.ManualOngoingG2.72.9 2.10Paint storage room is kept clean.ManualOngoingG2.8The following checks shall be performed during production:G2.91.4 2.11 2.12Paint Temperature.ManualPer Control Plan/Log Sheet (3/shift minimum)G2.101.4 2.11 2.12Viscosity.ManualPer Control Plan/Log Sheet (3/shift minimum)G2.111.4 2.11 2.12% Solids (by weight).ManualPer Control Plan/Log Sheet (1/Day minimum)G2.121.4 2.11 2.12Volume (paint depth in coating vat).Automatic/ManualPer Control Plan/Log Sheet (3/shift minimum)G2.131.4 2.11 2.12Vibratory feed tables are cleaned (if used).ManualPer Control Plan/Log Sheet (as needed)G2.141.4 1.17 2.11 2.12Basket condition (basket mesh clean and undamaged).ManualPer Control Plan/Log Sheet (as needed)G2.151.4 2.11 2.12Paint and/or solvent additions are documented.ManualPer Control Plan/Log Sheet (each addition)G2.162.10Viscosity cups are cleaned after each use.ManualPer Control Plan/Log Sheet (each check)G2.172.14 1.17Viscosity cups are verified.Manual2/Month minimumG2.182.14 1.17Thermometers are calibrated/verified.ManualOnce/Month minimum3.0Application ParametersG3.11.4 1.6A system is in place to ensure proper basket weights for specific parts, such as processing manual, traveller, or process recipe.Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.21.4 1.6Baskets are kept less than 2/3 full.Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.31.4 1.6Dip time is controlled.Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.41.4 1.6Spin speed (RPM) is controlled.Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.51.4 1.6 1.17The coating unit has an attached RPM indicator.G3.61.4 1.6 1.17RPM's can be adjusted easily.G3.71.4 1.6Spin time is controlled.Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.81.4 1.6The number of spins is adjustable (single, double, triple).Automatic/ManualG3.91.4 1.6Tumble time is in/out of coating controlled (if applicable).Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.101.4 1.6 1.17There is an adequate system to keep parts level going into the oven (raking, vibe table, etc.).Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.112.10Vibratory feed tables are cleaned (if used).ManualPer Control Plan/Log Sheet (as needed)G3.122.9There is evidence of steps taken to assist in soft handling of parts (shallow drops, lined chutes and hoppers, bumper boards, etc.).Automatic/ManualPer Control Plan/Log Sheet (each lot)G3.131.4 2.9 2.11Parts are cool to to touch before each coating step.ManualPer Control Plan (each lot)4.0Cure (See Convective Cure Process Table I)

Index PageCover Page

CQI-12 PROCESS TABLE HPROCESS TABLE H - AutophoreticAll 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.Item #Related CSA Question #Category/Process StepsControlMonitoring1.03.1Coating BathH1.11.4 2.11 2.12Mixer speed and direction are monitored and adjusted.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H1.21.41.62.112.12Time (hoist program) is verified.Automatic/ManualPer Control Plan/Log Sheet (1/day minimum)H1.31.41.172.112.12Conveyor speed is verified (if applicable).ManualAnnually or after repairH1.41.41.62.112.12Temperature is monitored and controlled.AutomaticPer Control Plan/Log Sheet (1/shift minimum)H1.51.4 2.11 2.12Humidity level is monitored.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H1.61.4 2.11 2.12101 (fluoride) and ORP levels are checked.Automatic/ManualPer Control Plan/Log Sheet (every 2 hours minimum)H1.71.4 2.11 2.12Chemical concentration (% solids, starter/iron titration, conductivity) is checked and maintained.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H1.81.41.172.112.12Bath transfer is maintained.ManualPer PM schedule (1/year minimum)2.01.18Tap Rinse After CoatingH2.11.4 2.11 2.12Pump pressure or agitator speed is monitored.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H2.21.4 2.11 2.12Impurity concentration (conductivity) is checked.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)3.03.2Reaction RinseH3.11.4 2.11 2.12Chemical concentration (titration, conductivity, pH, Hach Meter Test) is checked and maintained.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H3.21.4 2.11 2.12Pump pressure or agitator speed is monitored.Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H3.31.4 2.11 2.12Temperature is monitored and controlled (if applicable).Automatic/ManualPer Control Plan/Log Sheet (1/shift minimum)H3.41.41.172.112.12There is a dump schedule.ManualPer Chemical Manufacturer's Guideline (minimum 3 times per year)4.0Cure (See Convective Cure Process Table I)

Index PageCover Page

CQI-12 PROCESS TABLE IPROCESS TABLE I - Convective CureAll 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.Item #Related CSA Question #Category/Process StepsControlMonitoring1.0I1.11.41.62.112.12Oven temperature set point and limits are checked and documented.Automatic1/shift minimum or at every material change. Per coating supplier recommendationI1.21.17Part temperature profile is monitored.Manual1/month minimumI1.31.41.62.112.12Proper cure time is maintained (if applicable).Automatic/ManualPer coating supplier recommendationI1.41.41.61.172.112.12Conveyor speed is maintained (if applicable).Automatic1/month minimum (after PM)I1.51.4 2.11 2.12Airflow is measured (if required by coating supplier).Automatic/ManualPer coating supplier recommendationI1.61.17Air filter change is scheduled.ManualPer oven manufacturer, filter supplier recommendationI1.71.17Thermocouple for oven control is calibrated.I1.82.13Cure testing is conducted by laboratory.ManualPer coating supplier recommendationI1.92.13Final color is monitored.ManualPer Control Plan/Log Sheet (1/shift or color change minimum)I1.102.13Film thickness/coating weight is monitored.ManualPer Control Plan/Log Sheet (1/shift or color change minimum)I1.112.13Gaugeability is checked (if applicable).ManualPer customer requirementsI1.122.13Paint adhesion is monitored.ManualPer Control Plan/Log Sheet (1/shift or color change minimum)

Index PageCover Page

CQI-12 PROCESS TABLE JPROCESS TABLE J - EQUIPMENTAll 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.PROCESS EQUIPMENTItem #Related CSA Question #PretreatmentPowder CoatE-CoatSprayDip/SpinA-CoatCureVerification FrequencyCalibration FrequencyComment1.12.14XXXXXpH Meter/ProbeDailyYearly1.22.14XXXXXXXTemperature ControllerAt Start-up2x/Year1.32.14XXRectifierAt Start-upN/A1.42.14XXXXXWet AnalysisPhosphate - 3hr min. Paint Lines - Before Run E-Coat - 1x/Shift min.N/A1.52.14XAtomic Absorption (Optional)1.62.14XXXXXXXFilters*N/A* As needed based on pressure.1.72.14XXXBalance1x/WeekYearly1.82.14XXCoductivity MeterBefore UseYearly1.92.14XXViscosity MeasurementHourlyMonthly1.102.14XThermocoupleN/A2x/YearMINIMUM REQUIRED TESTING CAPABILITY2.12.14XXXXXXSalt Spray Cabinet2.22.14XXXXXWater Immersion Tank2.32.14XEnvironmental Chamber2.42.14XCure Testing (chemical rubbing)2.52.14XXXXXXAdhesion Testing2.62.14XXXXXXThickness Testing2.72.14XXXXXXMicroscope (when applicable)2.82.14XFreezer (plastic substrate)2.92.14XLab Oven

Cover PageIndex Page

CQI-15 Cover Sheet Instrts CQI-15 WELDING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet1Facility 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.2Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.3Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the OperationsManager or Quality Manager shall be used.4Fax number: The fax number of the facility.5Number of Welding Employees at this Facility: The number of employees, salaried and hourly,associated with the welding operation at this facility.6Captive 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.7Commercial 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.8Date 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, 2006.9Date of Previous Assessment: List the date of the previous CQI-15 Special Process: WeldingSystem Assessment of this facility.10Type(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.11Current 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 lastassessment by the customer shall also be given.12Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from theoriginal 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 theimplementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.13Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the welder's organization.14Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).15Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.16Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.17Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Cover PageIndex Page

CQI-15 Cover SheetSpecial Process: Welding System AssessmentFacility Name:Address:Phone Number:Type(s) of Weld Processing at this Facility:Fax Number:Process Table A - Arc WeldingArc Stud/Fastener WeldingNumber of Welding Employees at this Facility:Flux Cored Arc WeldingGas Metal Arc WeldingCaptive Weld Organization (Y/N)Submerged Arc WeldingShielded Metal Arc WeldingCommercial Weld Organization (Y/N)Plasma Arc WeldingGas Tungsten Arc WeldingDate of Assessment:Gas Metal Arc Braze WeldingProcess Table B - Resistance WeldingResistance Spot WeldingDate of Previous Assessment:Projection WeldingResistance Seam WeldingHigh-frequency Seam WeldingInduction Seam WeldingMash Seam WeldingFlash WeldingProcess Table C - Laser WeldingNd YAG WeldingCO2 WeldingDiode WeldingWire FedProcess Table D - Solid State WeldingInertia Friction WeldingDirect Drive Friction WeldingFriction Stir WeldingFlash Butt WeldingResistance Butt WeldingUltrasonic WeldingCurrent Quality Certification(s)Date of Re-assessment (if necessary):Personnel Contacted:NameTitlePhoneEmail00000000Auditors/AssessorsNameCompanyPhoneEmail0000Number of "Not Satisfactory" FindingsNumber of "Needs Immediate Action" FindingsNumber of "Fail" Findings in the Job Audit(s) 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-15 Elements Section 1 - 5Special Process: Welding System AssessmentThe 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 GroupAssessmentQuestion NumberQuestionRequirements and GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionSection 1 - Management Responsibility & Quality Planning1.1Is 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.1.2Is 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.1.3Do 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.1.4How 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.1.5Is 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.1.6Does 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.1.7Are 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.1.8Are 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.1.9Are 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.1.10Is 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.1.11Has 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.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.1.12Does 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.1.13Is 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.1.14Are 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.1.15Does 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.1.16Is 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.1.17Does 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.1.18Are 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.1.19Is 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.1.20Has 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.1.21How 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.1.22What 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?1.23Is 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 Responsibility2.1Does 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.2.2Is 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.2.3Is 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.2.4Are 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.2.5Are 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.2.6Is part loading specified, documented and controlled?Loading parameters shall be specified, documented, and controlled. Examples include part load sequence and clamp sequence.2.7Is 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.2.8Is the handling, storage and packaging adequate to preserve product quality?The welders 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.2.9Are 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.2.10Are 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.Section 3 - Equipment / Facilities/Controls3.1Are 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.3.2Are 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.3.3Are 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.3.4Has 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.3.5Have 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.3.6Are 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.Section 4 - TOOLING/FIXTURING4.1Is 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)4.2Is 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.4.3Has 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.4.4Are the fixture components robust?Gas, air, sensors, control cables, etc. are adequately protected for the process environment.4.5Are 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)Section 5 - PROCESS CONTROLS AND CONFIRMATION5.1Does 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.5.1.1Logic has been established to effectively identify and address process or equipment faults.5.1.2With over rides or resets, logs must be maintained.5.1.3Weld faults audible, visible and line shut down.5.1.4At weld cycle interrupt, part must not be removed or passed until dispositioned by appropriate personnel.5.1.5Calibration of meters and system controls.5.1.6Inter-locking of previous operations have occurred and quality of parts has been verified before the next operation begins.5.1.7Secure backups of all programs and procedures (electronic preferred).5.1.8High/Low limit alarms established by actual data.5.1.9Process variables have been defined and developed by data and shown to be statistically capable.5.1.10Acceptable traceability (sequence/date coding)5.1.11All tooling and process changes are documented.5.1.12Documented welding procedures for each weld location and each process variable.5.1.13Change over procedure (filler material, fixtures)5.1.14Must have documented start-up and shut-down procedure.5.2Are 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 1.13.5.3How 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?5.4How 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.5.5Are 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.5.6Are 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:5.6.1Cut and etch5.6.2Part location, warping, gap, and dimensional requirements5.6.3Correct number of welds5.6.4Weld length/size5.6.5Weld location5.6.6Non Destructive Testing (NDT)5.6.7Spatter, undercut, porosity, discontinuities,5.6.8Weld direction confirmation5.6.9Destructive testing5.6.10Additional testing 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-15Job Audit Section 6 Proc.Section 6 - Job AuditThe 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 GroupJob Identity:Customer:Shop Order Number:Part Number:Part Description:Base Metal Specifications:Filler Metal Specification (if required):Welding Process(es):Question #Job Audit QuestionRelatedWSA Question #Customer or Internal RequirementJob (Shop) Order or Reference Documentation RequirementActual Condition (Objective Evidence)Pass / Fail / N/A6.1Has 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?1.85.15.26.2Has the logic been established to effectively identify and address process or equipment faults?5.16.3Are over rides or resets logs maintained?5.1.26.4Are weld faults audible, visible and does the line shut down?5.1.36.5If the weld cycle is interrupted, is the part controlled or contained until dispositioned by appropriate personnel?2.75.1.46.6Are the meters and feed back controls calibrated per established frequencies?5.1.53.36.7If applicable, is there an inter-locking of the previous operation and has the quality of parts been verified?5.1.66.8Are there secure backups of all programs and procedures (electronic preferred)?5.1.76.9Are high/low limit alarms established by actual data.5.1.85.1.16.10Have process variables been defined and developed by data and shown to be statistically capable?5.1.96.11Is there acceptable traceability (sequence/date coding)?5.1.105.1.112.32.76.12Is there traceability of all process and tooling changes?4.15.1.115.46.13Are there documented welding procedures for each weld location and each process variable?5.1.121.51.106.14Is there a documented change over procedure (filler material, fixtures)?1.55.1.133.66.15Is there a documented start-up and shut-down procedure?1.51.105.1.146.16Are process control parameters monitored at established frequencies?5.26.17Are 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?5.31.215.61.82.76.18How does the organization handle changes to process control parameters after initial customer approval and how do you notify your customer?1.65.41.221.166.19Are In-Process and Final Tests performed at established frequencies?1.85.56.20Are weld quality requirements clearly defined per customer specifications?1.95.6Each part may have one or more requirements determined by the welding specification. Parts must meet each requirement. List requirements below and validate.6.20.1Test Type:Test Method:Test Frequency and Quantity:Specification:6.20.2Test Type:Test Method:Test Frequency and Quantity:Specification:6.20.3Test Type:Test Method:Test Frequency and Quantity:Specification:6.20.4Test Type:Test Method:Test Frequency and Quantity:Specification: 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-15 Arc Welding Table APROCESS TABLE A- Arc Welding ProcessesThe 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 GroupAll 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. indicates that procedure should be reviewed and documented when necessary.Item #Related WSA Question #Category/Process StepsArc 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)Gas Metal Arc Braze Welding1.01.7, 1.8Arc welding specific essential variables which shall be addressed in the FMEA, control plan and welding proceduresA1.1Arc voltagexxxxxxA1.2AmperagexxxxxxxxA1.3Current type (AC/DCEN/DCEP)xxxxxxxxA1.4Wire feed speedxxxx1x1xA1.5Pulse setting variables specific to the OEM of the welding equipment must be documented and controlled.xxxxA1.6Stud gun/torch position work angle, travel anglexxxxxxxxA1.7Contact tip-to-work distancexxxxA1.8Electrode-to-work distancexxA1.9Lift height of studxA1.10Fastener coating (determines current type)xA1.11Plunge control mode force or positionxA1.12Flux classification and depthxA1.13Flux removal and reclaimation planxA1.14Gas flow pre-flow, post-flow, rate and type(s)x2x2xxxxA1.15Electrode and/or filler metal type, diameter, and classicifacationxxxxxx1x1xA1.16Travel speedxxxxxxA1.17Gas nozzle size and typex2x2xxxxA1.18Arc starting parametersxxxxxxA1.19Arc end parametersxxxxxxA1.20Wire burnback settingsxxxxA1.21Plunge depthxA1.22Arc timexx3x3x3x3A1.23Fastener geometry per material typexA1.24What are your procedures for:Nozzle cleaning and cleaners, replacementA1.25Tip changesA1.26Wire liners/conduits cleaning and replacingA1.27Drive roll changesA1.28Wire guide tube changeA1.29Antispatter Application (spray/dip and equipment)A1.30Electrode and stud collet changeA1.31O rings in gas system maintenanceA1.32Gas delivery and mixing systemx2x2xxxxA1.33Flux delivery systems maintenanceA1.34Flux removal (screens size and magnetic separators)A1.35Electrode sharpeningA1.36Slag removalxxxA1.37Wire dereelers maintenanceA1.38Wire brake adjustmentA1.39Integrity of ground systemx1: 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. 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-15 Resist.Welding Table BPROCESS TABLE B- Resistance Welding ProcessesThe 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 GroupAll 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. indicates that procedure should be reviewed and documented when necessary.Item #Related WSA Question #Category/Process StepsResistance 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)2.01.7, 1.8Resistance welding specific essential variables which shall be addressed in the FMEA, control plan and welding proceduresB2.1Weld forceXXXXXB2.2Clamp forceB2.3Forge forceB2.4Forge delayB2.5AmperageXXXXB2.6VoltageXXXXB2.7PowerB2.8FrequencyXXXXXXXB2.9PulsationXXXXB2.10Squeeze time/cyclesXXXXB2.11Weld time/cyclesXXXXXB2.12Hold time/cyclesXXXXXB2.13Quench time/cyclesB2.14Temper timeB2.15Cool time/cyclesXXXXB2.16Upslope time/cyclesXXXXXXXB2.17Stepper programsXB2.18Tip/electrode/wheel dressingXXXXXXB2.19Weld travel speedXXXXB2.20Adequate electrode follow up in weld force / distanceXXXB2.21System cooling-transformers, electrodes, etc.XXXXXXXB2.22Tip/electrode/wheel/coil change frequencyXXXXXXXB2.23Tip/electrode/wheel/coil alignmentXXXXXXXB2.24What are your procedures for:Electrode selection/type (material type etc.)B2.25Electrode geometryB2.26Induction coil geometryB2.27Secondary loop electrical conductors (cables, leaf shunts, etc.) and mechanical joints maintenanceB2.28Projection 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)

Cover PageIndex Page

CQI-15 Laser Welding Table CPROCESS TABLE C- Laser Welding ProcessesThe 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. indicates that procedure should be reviewed and documented when necessary.Item #Related WSA Question #Category/Process StepsNd YAG (LBW)CO2 (LBW)DIODE (LBW)With Wire Feed System3.01.7, 1.8Welding specific essential variables which shall be addressed in the FMEA, control plan and welding proceduresEquipmentC3.1Beam qualityXXXXC3.2Optic cleanlinessXXXXC3.3Cross jet or laser knifeXXXXC3.4Beam configuration (split, single)XXXXC3.5Focal lengthXXXXC3.6Beam spot sizeXXXXC3.7Gas tube angle/arrangementXXXXC3.8Optics purge gas (flow and quality)XXC3.9Mirror cleanlinessXXXC3.10Mirror degradationXXXC3.11Beam sharingXXXXC3.12Split beamXXXXC3.13Tip changesXC3.14O rings in gas systemXC3.15Gas nozzleXC3.16Torch anglesXC3.17Chillers (internal - external)XXXXC3.18- Flow rateXXXXC3.19- Water qualityXXXXC3.20- Type of coolantXXXXC3.21- Additive concentrationXXXXC3.22- Temperature control (rate of change and range)XXXXC3.23Wire feed systemXC3.24- Wire feed speedXC3.25- Wire liners/conduits cleaning and replacingXC3.26- Drive roll changesXC3.27- Wire guide tubeXC3.28- Wire derealersXC3.29- Wire brake adjustmentXC3.30- Wire cleaners/wipersXC3.31- Contact tip to work distanceXC3.32- Wire position to laser focal pointXBeam DeliveryC3.33DirectXXC3.34FiberXXXC3.35- Fiber diameterXXXC3.36- Fiber lengthsXXXC3.37- Bend radiusXXXC3.38- Condition of fiberXXXC3.39- Fiber ends (condition of fiber ends)XXXC3.40- Fiber end coolingXXXC3.41MirrorXXC3.42- Power loss though the delivery systemXXC3.43- AlignmentXXC3.44- CleanlinessXXC3.45- Coatings of mirrorXXC3.46- Mirror typeXXC3.47- Optic and mirror coolingXXProcess VariablesC3.48Shielding gas type - flow rateXXXXC3.49Weld travel speed control (rate of change, and velocity control)XXXXC3.50Power Output ControlXXXXC3.51Power ramping/program (start, weld, end)XXXXC3.52Power at the work pieceXXXXC3.53Offset of beam to jointXXXXC3.54Continuous waveXXXXC3.55PulsationXXXXC3.56Angle of IncidenceXXXXC3.57Focus pointXXXXC3.58Direction of welding (trailing or lead)XXXXC3.59Beam quality burn-inXXXXC3.60Power output control calibrationXXXXC3.61Plasma suppressionXXC3.62- Monitoring Back scatter for control processFixtures/PartC3.63- Stability and/or vibration isolationXXXXC3.64- Articulation system (smoothness of motion and accuracy)XXXXC3.65What are your procedures for controlling:Part fit upC3.66Seam trackingC3.67Edge conditionC3.68Coatings 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-15Solid State Weld. Table DPROCESS TABLE D - Solid State Welding ProcessesThe 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. indicates that procedure should be reviewed and documented when necessary.Item #Related WSA Question #Category/Process StepsInertia Friction Welding (FRW-I)Direct Drive Friction Welding (FRW-DD)Friction Stir Welding (FSW)Flash Butt Welding (FW)Resistance Butt Welding (UW)Ultrasonic Welding4.01.7, 1.8Welding specific essential variables which shall be addressed in the FMEA, control plan and welding proceduresD4.1Tolerances on axial alignmentXXXD4.2Faying surface areaXXXD4.3Faying surface cleanlinessXXXD4.4Initial spindal speedXXXD4.5Welding spindal speedXD4.6Spindal torque - to not damage equipmentXXXD4.7Flywheels; total moment of inertiaXD4.8Spindle clamp pressureXXXD4.9Fixture clamp pressureXXXD4.10Part stickoutXXPreheat (First friction phase) if neededD4.11-Projection on faying surfaceX1X1D4.12-Preheat forceX1X1D4.13-Preheat time or RPMX1X1D4.14Preheat burnoff length-amount of dimension loss during preheatX1XXWeld Heat (Second friction phase)D4.15-Friction weld forceXXD4.16-Friction speed at which forging beginsXXForging StageD4.17-Forging speedXXD4.18-Forge forceXXD4.19-Forge timeXD4.20-Forge length if limited upset is usedXD4.21-Forge delayXD4.22-Upset distanceXD4.23-Upset removal / managementXXD4.24-Upset hold timeXXD4.25-Upset rateXXD4.26-Friction upset distance and timeXD4.27Brake setting or stopping time dimensions and tolerencesXD4.28Brake forceXD4.29Brake delay prior to upsetXD4.30Final positionXD4.31Postweld heat treatment if needed based on materials joinedD4.32Protective atmosphere if necessary for the base materialD4.33Total burnoff-amount of dimension loss during total processXXXFSWD4.34Primary control (position or force)XD4.35Tool to weld joint alignment during length of travelXToolD4.36-Pin to shoulder ratioXD4.37-Pin lengthXD4.38-Included angle for pinXD4.39-Included angle for shoulderXD4.40-Thread on pin surfaceXD4.41-Pin materialXPlunge PracticeD4.42-Speed of plungeXD4.43-Spindal speed during plungeXD4.44-Preheat dwell time after plungeXD4.45-Plunge forceXWeldD4.46-Weld forceXD4.47-Travel speedXD4.48-Tool tilt angleXD4.49-Weld spindal speedXWeld terminationD4.50-Exit motion of tool such as tilt angle rotationXD4.51-Spindal speed at tool extractionXD4.52-Dwell at end of travelXFBW RBWD4.53Electrode design-eliminate die burnsXXD4.54Electrode/Die cleanlinessXXD4.55Electrode/Die clamping pressureXXD4.56Part cleanliness and scale removalXXD4.57Part alignmentXXD4.58Joint geometry preporationXXD4.59Initial martial stickout or extension beyond electrodesXXPreheatD4.60-Preheat forceXXD4.61-Tap selectionXXD4.62-Percent heatXXD4.63-Off time during initial die openingXInitial FlashingD4.64-Initial die openingXD4.65-Initial flashing rateXD4.66-Type of platten movement (linear or parabolic)XD4.67-VoltageXD4.68-Initial flashing distance or timeXD4.69-Percent heatXD4.70-Tap selectionXFlashingD4.71-Flashing rateXD4.72-Type of platten movement (linear or parabolic)XD4.73-VoltageXD4.74-Flashing distance or timeXD4.75-Percent heatXD4.76-Tap selectionXWeld Stage 1D4.77-Percent heatXD4.78-Tap selection voltageXD4.79-ForceXD4.80-Pulsation (on, off and number of pulses)XD4.81-Off time before stage changeXWeld Stage 2 (can be multiple stages with different parameters)D4.82-Percent heatXD4.83-Tap selection voltageXD4.84-ForceXD4.85-Pulsation (on, off and number of pulses)XForge/UpsetD4.86-Forge rateXXD4.87-Forge forceXXD4.88-Forge distance / total upsetXXD4.89-Upset timeXXD4.90-Upset currentXXD4.91-Flashing voltage cut offXD4.92-Flashing removal / managementXXPost weld heat treatment if neededD4.93-Heat treatment clamping distanceD4.94-Quench timeD4.95-Tap selectionD4.96-Precent heatD4.97-Temper timeD4.98Final die openingXXUltrasonic Metal weldD4.99Tap selection / design of ribbon structureD4.100Frequency of power supply for application (40/30/20kHz)D4.101Fixture & part design with max dimension deviation and material specsUpset and Monitoring (windowing)D4.102Welding-EnergyXD4.103Welding-TimeXD4.104Welding-AmplitudeXD4.105Welding-ForceXD4.106Welding-CurrentXD4.107Welding pre Height and travel (compaction)XD4.108Energy with height compensationXD4.109Weld Head CoolingD4.110Environmental conditions control (i.e., temperature, humidity, dust, etc.)D4.111TAP/Die cleanlinessD4.112TAP/Die clamping pressureD4.113Part cleanliness and scale removalD4.114Part alignmentx1: If required to achieve heat balance. Example thin part to thick part or various hardnesses. 2010 Automotive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-17 COVER SHEET INSTRTS.CQI-17 SOLDERING SYSTEM ASSESSMENTInstructions for completing the Cover Sheet1Facility 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.2Address: The street address of the facility being assessed; P.O. Box numbers may be given asadditional information.3Phone Number: The phone number of the facility.If there is no common phone number for the facility, the phone number of the OperationsManager or Quality Manager shall be used.4Fax number: The fax number of the facility.5Number of Soldering Employees at this Facility: The number of employees, salaried and hourly,associated with the soldering operation at this facility.6Captive 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.7Commercial 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.8Date 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, 2006.9Date of Previous Assessment: List the date of the previous CQI-17 Special Process: SolderingSystem Assessment of this facility.10Type(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.11Current 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 lastassessment by the customer shall also be given.12Date of Re-assessment (if necessary): If "Not Satisfactory" findings were observed from theoriginal 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 theimplementation of the corrective action(s), has been observed. Also, the "Number of NotSatisfactory Findings" shall be modified as appropriate.13Personnel Contacted: List the name(s), title(s), phone number(s), and email address(es), ifavailable, of the principal participants from the solderer's organization.14Auditors/Assessors: List the name(s), Company(ies), phone number(s) and email address(es), ifavailable, of the auditor/assessor(s).15Number of "Not Satisfactory" Findings: Enter the number of "Not Satisfactory" findingsobserved during the assessment.16Number of "Needs Immediate Action" Findings: Enter the number of "Needs ImmediateAction" findings observed during the assessment.17Number of "Fail" Findings in the Job Audit(s): Enter the number of "Fail" findings observedfrom the job audit.

Cover PageIndex Page

CQI-17 Cover SheetSpecial Process: Soldering System AssessmentFacility Name:AddressPhone NumberType(s) of Soldering at this Facility:Fax NumberProcess Table A -Process Table K -Number of Soldering Employees at this Facility:Process Table B -Process Table L -Captive Soldering Organization (Y/N)Process Table C -Process Table M -Commercial Soldering Organization (Y/N)Process Table D -Process Table N -Date of Assessment:Process Table E -Process Table O -Date of Previous Assessment: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 -Current Quality Certification(s)Date of Re-assessment (if necessary):Personnel Contacted:NameTitlePhoneEmail00000000Auditors/AssessorsNameCompanyPhoneEmail0000Number of "Not Satisfactory" FindingsNumber of "Needs Immediate Action" FindingsNumber of "Fail" Findings in the Job Audit(s) 2010 Automortive Industry Action Group (AIAG)

Cover PageIndex Page

CQI-17Sect. 1&2 - Gen. OverviewSpecial Process: Soldering Process Assessment (General Facility Overview)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.AssessmentQuestion NumberQuestionRequirements and GuidanceObjective EvidenceN/ASatisfactoryNot SatisfactoryNeeds Immediate ActionSection 1 - Management Responsibility and Quality Planning1.1Is 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.1.2Does 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.1.3Are 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.1.4Are 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.1.5Are 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.1.6Is 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.1.7Has 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 processe